Canyon Bicycles, a leading bicycle manufacturer, has revolutionized mountain bike design by using 3D printing technology. This article will show you how Canyon has leveraged 3D printing to produce more efficient, durable, and highly customizable mountain bike frames.
1. Introduction to Canyon
Canyon, a well-known name among cycling enthusiasts, has solidified its position as one of the world's leading bicycle manufacturers. Offering bicycles in every category from city bikes to mountain bikes, Canyon has partnered with professional cyclists such as Jan Frodeno, Alejandro Valverde, and Mathieu van der Poel
With the motto of always leading in innovation, Canyon continuously seeks advanced technologies to create high-quality bicycles that meet all users' needs. One of Canyon's breakthroughs is applying 3D printing technology in the production of mountain bikes.
2. Why did Canyon choose 3D printing technology for production?
Currently, developing a new bike frame is often complicated, time-consuming, and expensive. This process starts with design, mold creation (if necessary), welding steel tubes and attaching them to components, followed by frame shape testing. If issues arise, engineers must return to the design stage, a task that can take weeks or even months.
For carbon fiber frames, creating a prototype is even more challenging, as each design iteration requires a new milled mold. This can take several weeks before the final frame is completed for evaluation and modification.
However, with 3D printing technology, these limitations are no longer an issue. Engineers can print the frame shape designed on the computer within a day or two using the BigRep ONE FDM 3D printer. Engineers only need to design, simulate, print, check the frame, modify, and quickly reprint if necessary.
3. Why did Canyon choose to use the BigRep ONE?
3.1. FDM 3D Printer - BigRep ONE
The BigRep ONE is an award-winning large-format 3D printer offered at a reasonable price and trusted by designers, innovators, and manufacturers worldwide. With a massive 1-cubic-meter build volume, the BigRep ONE enables rapid and precise prototyping, production, and realization of 3D designs.
(FDM 3D Printer - BigRep ONE)
Impressive printing capabilities
Large build volume: With a build volume of up to 1 cubic meter (1000 x 1000 x 1000 mm), the BigRep ONE allows for the printing of large objects without needing to split them into smaller parts. This opens up endless applications across various industries, from automotive manufacturing to architecture.
Smart and user-friendly design
Sturdy structure and intuitive user interface: The printer is designed with a robust, transparent structure along with easy-to-use control software, making it simple for users to set up and monitor the printing process, ensuring stability throughout.
Versatile applications
The BigRep ONE is widely used for producing product prototypes, manufacturing tools such as molds, and large-scale architectural models, enabling designers to evaluate and refine their products before mass production.
3.2. A modern and rapid mountain bike frame production process using 3D Printing technology with BigRep ONE
For this project, Canyon's R&D department was tasked with developing a bike frame that could set higher sustainability standards. The frame had to be made from a recyclable material and stay within a maximum weight limit. Additionally, it needed to be extremely rigid to ensure safety in harsh professional racing conditions, as well as for amateur riders.
3.2.1. Detailed 3D design:
To meet all these goals, Canyon implemented structural design and optimization using advanced software. Several software solutions support both 3D design and simulation calculations, such as Materialise 3-Matic, Hexagon, and nTop.
Using specialized CAD software: Canyon's engineers used computer-aided design (CAD) software or specialized software in the bicycle industry to create detailed 3D drawings of each component.
Design optimization: After creating the 3D drawings, the engineers performed simulations and optimized the design to ensure that each part had high durability, light weight, and was suitable for its function.
After a few setups, the computer calculated the ideal shape for the new mountain bike frame. The setup and adjustments were made continuously until the most optimal shape was achieved.
Related Knowledge:
Top 8 best 3d design softwares today
3.2.2. Preparation for Printing:
Material selection: Depending on the characteristics of the part to be produced, engineers select the appropriate printing material. Common materials used in 3D printing for bicycles include PLA, ABS, TPU, Nylon, and Carbon.
Slicing: The printer control software slices the STL file into thin layers, which serves as the basis for the 3D printer to create the final product. Materialise Magic is considered one of the most reliable and professional slicing software available today.
Learn more: All about 3d printing materials: plastic
3.2.3. 3D Printing
The BigRep ONE FDM 3D printer performs automatic printing with its high-power extruder (PEX), which can handle single or dual extrusion. Due to its large size, the BigRep ONE can print large bike parts in a single run, meeting the production needs for frames and other components.
Key Features of the BigRep ONE:
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During the printing process, the print head moves along the X, Y, and Z axes to create thin layers of material stacked on top of each other until the final product is formed. The printing process usually includes cooling to ensure the material hardens and adheres well. Compared to other FDM 3D printers, the BigRep ONE has faster print speeds and higher accuracy, reducing production time to just 2-3 days. The BigRep ONE is undoubtedly the perfect choice for research and product development.
3.2. 4. Product finalization
Detaching the product from the print bed: Once the printing process is complete, the product is removed from the print bed.
Post-processing: Depending on the material type and surface quality requirements, the product may undergo the following post-processing steps:
Removing excess material and support structures: Tools or machines are used to remove excess printed material and support structures.
Surface treatment: The product’s surface is smoothed or polished.
Painting: A protective coating or paint is applied to enhance aesthetics and durability.
Learn more: Post-processing metal 3D printed parts: procedures and key considerations
3.2.5. Inspection and Assembly:
Dimension and shape check: Ensure that the product matches the original design in terms of size and shape.
Strength testing: Perform durability tests to confirm the product meets technical requirements.
Assembly: The product is assembled into the bike and undergoes functional checks.
(Quality Inspection of 3D FDM Printed Products)
4. Benefits and Limitations of the Project
Benefits:
Innovation: Canyon is pioneering the use of 3D printing technology in bicycle manufacturing, creating unique and competitive products.
Flexibility: 3D printing allows Canyon to easily adjust designs and quickly produce new products.
High customization: 3D printing enables the production of complex bike components that precisely meet the size and shape requirements of individual users, leading to more comfortable, personalized bikes.
Reduced time and cost: The design and manufacturing processes are significantly shortened, lowering production costs and accelerating the time to market.
Material diversity: Engineers can experiment with a variety of materials, ranging from plastics to metals, using this technology.
Limitations:
Investment cost: The investment in industrial 3D printers and software is quite high.
Surface quality: The surface of 3D printed products may require additional finishing work for a smooth appearance.
Expert knowledge: Operating the BigRep ONE FDM 3D printer requires skilled engineers with a good level of expertise.
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5. Future prospects
With the benefits that 3D printing technology brings, it is predicted that this technology will be increasingly applied in the bicycle manufacturing industry. Manufacturers will be able to create bikes with more complex, lighter, and stronger designs. Additionally, production costs will decrease, making bicycles more accessible to consumers.
3D printing technology is proving its power and potential, not only in bicycle manufacturing but also opening new doors for many other industries. Below are some prominent future applications of 3D printing:
Healthcare:
Anatomical modeling: 3D printing helps create detailed 3D models of organs, assisting doctors in surgery and treatment planning.
Printing replacement parts: 3D printing of replacement parts such as bones, joints, and teeth using biocompatible materials that work with the human body.
Related Information: VTV24 - Over 8 hours of surgery successfully removing a giant bone tumor thanks to the application of 3D technology
Automotive
Customized parts: 3D printing allows for the creation of customized interior and exterior components based on customer preferences.
Prototypes: It enables rapid prototyping to test new designs before mass production.
Architecture and Construction:
3D-printed structures: This technology can print building structures such as walls, columns, and even complete houses, reducing construction time and material costs.
Architectural models: Detailed, vibrant architectural models can be created for client presentations.
Aerospace:
Prototypes: 3D printing allows for rapid and efficient production of prototypes to test new designs.
Complex parts: It enables the manufacturing of molds and components with complex shapes that are difficult to process using traditional methods.
Fashion and Art:
Footwear: 3D printing can create unique and personalized shoe designs tailored to individuals.
Jewelry: It allows for the production of customized, one-of-a-kind jewelry pieces.
Artworks: Unique 3D sculptures and artwork can be created using this technology.
With Vinnotek, you won't just own a 3D printer; you'll also gain the knowledge and skills to confidently operate it and create unique products.
Looking for a solution to bring your creative ideas to life? Vinnotek is your reliable companion. We provide a full range of services, from supplying industrial FDM 3D printers (BigRep, Raise3D, Mingda), advanced metal 3D printers (SLM Solutions), and professional design software (Materialise, Hexagon) to offering in-depth training and design simulation services.
Let Vinnotek help you explore the world of 3D printing. With our diverse, high-quality services, we are committed to delivering the most comprehensive and outstanding experiences.
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