Pinarello made a special 3D printed titanium aerobar for their sponsored triathlete, Cameron Wurf. The uber-biker rode them to a 5th place finish at last weekend’s Ironman World Championship in Kailua-Kona, Hawaii. The bars will be available in custom sizing for any custom willing to wait the two-month lead time.

Images courtesy Pinarello.

Pinarello custom 3D printed MOST aerobar for Ironman triathlete Cameron Wurf

Pinarello is making more and more developments for triathletes, and they’ve turned their focus to custom aerobars. Their latest project is a 3D printed titanium aerobar for Cameron Wurf, one of the top long-distance triathletes (something that was already done in 2015 for Bradley Wiggins’ hour record attempt). Cameron rode the bar to a 5th place finish at last weekend’s Ironman World Championship, with a bike split of 4:14:45 for the 112 mile course.

The bar was designed using CAD and 3D modeling, and manufactured with what Pinarello is calling Titanium Powder Bed Fusion Technology. The shape of the bar was determined with CFD analysis, and is said to be more efficiently made with 3D printing than CNC machining or carbon molding. Additionally, 3D printing allowed the removal of bolts from the system, reducing overall weight to 780g without paint.

The bars are for sale (with price TBD), and require a two-month lead time for manufacturing. Weight will vary based on the custom size of the bar.


  1. Ettore on

    At this time, it’s not that much cheaper to 3D print a part like this, than it is to have a mold made in the Shenzen area and have the part layed up in carbon fiber. The only advantage is lead time. The print is done much sooner. So this might be a time pressure or a “look at us and our futuristic tech” decision.

    • roadstain on

      But…”3D Printed”…years ago I had custom (Ti) extensions on a base bar (Profile Carbon-X). These were the most comfortable aero bars ever (for me). Rather than trying to reinvent the wheel, just manipulate a readily available design. At the end of the day, the base bar looks to be the same as every other base bar (for the most part)

      • TruckNutZ on

        The base bar is of zero concern in this setup (therefore it replicates the stock Pinarello basebar), the extensions are the focus…angle, width, and how it mates to the forearm.

        Custom molded & 3D printed extensions have become the new secret sauce for top TT’ers & triathletes (for whatever it’s worth…)

          • TruckNutZ on

            @Roadstein…What you are missing here is this bar is totally about the extensions (ignore the base bar component, that isn’t the story here).

            The extension’s tops are shaped to mate with the forearms of the rider creating a seamless contact to the arms and in theory a more aero setup.

            The aero extensions and riders forearms become a seamless unit.

            This where the 3D printing (ti) or molding (carbonfiber) come into play (and the outrageous costs).

            But as mentioned, all the serious players( and deep pocketed amateurs) are starting to use these style extensions

  2. Exodux on

    I think your missing the point. With 3D printing, you have the ability to customize every bar made. With carbon fiber you have to make a mold, which seriously limits the customization. When using welded or bonded metals, you have to make a fixture, which again limits the customization procedure,
    With 3D printing, is all derived from a cad drawing and can easily be customized.

    • Ettore on

      I think you’re missing my point. For every custom design, you can make a custom mold, and still come to the same price as the 3D printed bar, because the printing is crazy labour intensive for the machine. You’re letting a 500.000-million USD machine run for 12-24 hours.

      • Exodux on

        So making molds for say 1000 people with different fitment issues is more cost effective than 3D printing? I think not.
        The 500,000- 1M dollar printer, you mention, which is way on the high side any more.
        With the 3D printing machines, they are still useful after the fact, whereas a mold is pretty much a one shot deal( per custom fitment)

        I’m sorry I disagree with you, but 3D printing is the future for a lot of customizable products


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