World's First Single-Part 3D Printed Carbon Fiber Bicycle Frame
As the sole industrial designer at Arevo/ Superstrata, I was challenged with translating an initial marketing concept design from idea to reality. I worked hand in hand with a large team of software and robotics engineers to refine CAD surfacing and topology generation techniques to build foundational methodologies for designing around Arevo's proprietary carbon fiber printing technology. During my time there, we were able to ramp up to 3D print full carbon fiber bicycle frames in one shot at production scale. A feat never before accomplished. At the same time we fulfilled preorders for over 3000 bikes (during covid) for one of the most successful indegogo campaigns in history.
Through development, I generated countless iterations of bike sizing and tube surfacing geometry for both standard and e-bike variations to fit riders ranging in size from 4'10 - 6'11, while ensuring manufacturability, functionality, structural integrity and maintaining design-intent within the functional constraints of the 3D printing technology.
The highly iterative process of 3D printing allowed for continuous refinement and development through early production. I worked alongside our engineers to develop functional, process and manufacturing efficiency improvements as well as redesign multiple aspects of the frame and fork to improve stiffness, weight savings, and streamline assembly, resulting in significant quality improvements and cost savings compared to the initial production prototypes.
In August of 2022 I traveled to our 3D printing production facility in Ho Chi Minh City, Vietnam where I spent 4 weeks working on-site with to help oversee production, support component sourcing and supply chain, and help institute QC protocols of the final run of bikes.
Production Model
Photography Provided by Arevo