There were many uses of 3D printing at the MADE show, but perhaps none that jumped out as much as the latest creation from TBD Bikes. That’s the name of the company that Dylan Banera is sticking to, with a focus on 3D printed bicycle designs.
If that name sounds familiar, that’s likely because we just covered Dylan’s work earlier this year at Sea Otter. At the time, Dylan tells us that the new bike on display at the MADE show wasn’t even in the works. Dylan was able to design a bike frame, get those design files printed in China, and then get the bike assembled, all in time for MADE. That’s a pretty eye-opening demonstration of how quickly a bike can go from concept to finished prototype with the use of 3D printing.
Compared to his last frame, which was an unridable proof-of-concept, Dylan wanted to create a frame that was rideable. So instead of carbon tubes bonded to Nylon 12 lugs, the new bike is almost completely 3D printed from aluminum.
There’s a lot going on with the design, but the most striking elements are likely the head tube and bottom bracket area, both of which were created utilizing AI-based design software. According to Dylan, he simply wanted to try out the feature after exploring it in his design software.
The result is a bottom bracket assembly that vaguely resembles a human pelvis, complete with a shelf meant to add tension for a belt-drive setup. There doesn’t seem to be a split in the frame to allow for belt use, so it’s unlikely to be utilized.
Before sending off the files to be printed in metal, Dylan printed sections out of plastic to make sure they’d work.
The other interesting design feature is the use of TPMS or Triply Periodic Minimal Surfaces for the tubing, which Dylan admits is way overkill for the intended purpose. These continuous, interconnected surfaces are great for heat exchangers and the like due to a high surface area and structural efficiency, but probably not necessary when a hollow tube would suffice. But they look cool.
If that wasn’t enough for the average teenager, Dylan is also working on a frame that will utilize fully 3D-machined and bonded to carbon tubes for another rideable bike.
