2016 NAHBS: Bastion Cycles 3D Printed Ti and Carbon Road

The technology is there and a few builders are utilizing it for sure, but you don’t often see a 3D printed frame with elegance like Bastion Cycles‘ titanium and carbon road bike. This thing is a beauty and for me, was a pleasure to photograph. I love the contrast of materials, the 3d-printed NAHBS insignia on the driveside dropout and the mean fuckin’ stance of this road bike. See for yourself in the gallery!

  • Nicholas Petersen

    Those wheels suit this bike so well.

    • Bananas87

      This bicycle is awesome! Kind of reminds me of the old giant cadex frames…

    • Yeah, nice wheels from Curve Cycling, another Melbourne based company.

  • Noel Smith

    yowza.. I can only imagine how this must ride. looks like a magic-carpet on wheels..

  • FireUrEngine

    That’s one mean looking hefty fork. Who makes that fork?

  • Tony Clifton

    According to Bastion, the lugs are made from Grade 5 titanium with the Selective Laser Melting process, which uses lasers to melt powdered metal into a sintered mass according to a 3D CAD design. I wonder how the cost and strength compares to CNC machining the parts from 6-4 bar stock.

    • Bastion Cycles

      Hi Tony, the lugs can’t be machined from stock. We use a 0.5mm wall thickness and internal lattice like mesh structure. We have leveraged the technology meaning it is the only process capable of creating them. The strength is basically as good as forging, and much better than casting.

      • Andy Moore

        Brilliant application of technology @bastioncycles:disqus ! #chapeau!

  • somebody_aight

    that carbon weave makes me hungry for some farfalle

  • Jonathan Gresley

    just… Wow

  • Joe Chase

    Beautiful bike. How long until I can 3D print my own components?

    • tony365

      They are getting close. Polaroid is releasing 3-D printers in the UK for not that much money and the technology has been around for 30 some years. They used to call it Rapid prototyping. It will be possible in the next ten years if you have the resources ( in my belief ) to design and produce your components, with out to much trouble, but your your own test pilot?

      • Joe Chase

        Good point. Although the 3D Ti Print technology is emerging, I’m sure Bastion performs the proper critical mechanical tests on printed pieces. However, if I were to 3D print bike components, all I I have is a hammer and a cinder block in my backyard for testing.

    • Closest thing to 3D printing end-use objects: https://markforged.com/

    • gvnstewart

      I have 3d printed headset spacers and dust caps for top headset cuts, repaired broken frames by printing permanently affixed internal mandrels (then wrapped carbon around to join and strengthen, and played around a bit with printing molds that can be dissolved (with just water) after the carbon has cured. You can also print parts and then use them as investments for lost wax casting aluminum! The tech is there- just waiting for you to use it for something awesome. You can design parts and have Shapeways or a number of other companies produce/3d print the parts in a plethora of materials from Ti to stainless to regular old plastic.

      • Joe Chase

        That’s awesome, I really have not followed the 3D printing scene – especially for bikes. I’m glad to know someone is alpha testing this tech for the rest of us lazy bums.

    • ABW

      Depending on the component, now. For simple parts that don’t require a lot of strength (headset spacers as mentioned below), the tech is here now and is easy to find – my public library has a basic-but-nice 3D printer that you can check out by the hour (you pay material costs, kind of like making copies). If you need something more complex or stronger, changes are good you’re fairly close to some kind of “maker” space, which are usually like a coop and full of really smart, really creative people who would love to help you out.

  • mauro tittoto

    congratulations to Bastion Cycle! love this work nice concept & amazing realization.

    • Bastion Cycles

      Thank you!

  • Andy Moore

    SICK!!!

  • Eric Channing Brewer

    It’s beautiful! I would replace my Lemond ti-carbon spine bike with this or compliment it with a wide tire gravel version. Any chance of that possibility as the thru axles might suggest?

    • Bastion Cycles

      Hi Eric, we have done and are continuing to do many kms on gravel with this model. It is intended to be an all-road offering. It can run 28s, but even on the 25s we have tested with it is great on gravel.

      • Andy Moore

        28s do not count as wide tires, @bastioncycles:disqus . Not here, anyway!

        Let’s see one that can handle 45s w fenders. ;)

        • Bastion Cycles

          @disqus_fJPp19pfMC:disqus Wide ROAD tires… :) We are still deciding the specifications for the future CX version, but 45s should be covered.

  • Chris Dolan

    Wow, the carbon weave on that frame is gorgeous! You could wear that frame as jewelry. If only the fork matched…

  • ROTOMON

    Top Notch bar taping there. That carbon finish is amazing.

    • Bastion Cycles

      Thanks for noticing! We were pretty proud of the bar taping too. It is the little things that make a custom bike special.

  • Ryan Kennedy

    OH my.

  • Talabardio

    I love the concept and execution here. The description of the interactive features to be added to the website are extremely intriguing. Does anyone have any idea of what a frameset would cost?

    • Bastion Cycles

      Framesets start at $7,500 AUD ($5,400 USD) and we are taking deposits until the ordering and design system goes live. It is undergoing the second phase of testing now and then it will go live later this month.

  • At first glance I thought I don’t like…and 3D printing WTF I thought…then I looked more closely…this is executed perfection.

  • bloibl

    seems like a bit of a step backward. gluing and bonding to what end. this looks a bit like an old Miyata from the Greg Herbold days.

    • It’s what Colnago, Parlee and others still do to this day. In fact, almost all carbon frames have some sort of bonding agent in them.

      • bloibl

        never mind, its beautiful.

        • White Mike

          lol

      • Bastion Cycles

        Thanks John! As you say, there is literally no such thing as a true monocoque. Trek, Specialized, Giant and the rest all have joints hidden under the paint.

    • Eugene Chan

      The main thing about Bastion is logistics. They are all about cost savings and quick delivery. You use their web application to fully customize your frame geometry and they can 3D print the titanium joints immediately, then cut the tubing to the right size. Suddenly a fully custom frame takes a couple weeks to ship rather than several months. Plus the manufacturing scales instead of relying on skilled welders or machinists to make the titanium parts. They truly want to streamline everything, that means no wasted man-hours on sanding down poorly finished 3D printed parts or waste product (support pieces used in the printing process.) They were the most interesting booth to visit for me at NAHBS. The finished product looked really good. Definitely something I’d consider for my next bike.

  • Alex Rhino

    Jeez. This thing is insane! First Carbon bike that I’ve enjoyed looking at. What is 3D printed and what material is it printed with?

    • Andy Moore

      Check the Bastion website to read how they are printing w Ti! Mindblowing schtuffs.

    • Bastion Cycles

      Hi Alex, the lugs are 3D printed in Ti6Al4V Titanium alloy. The tubes are made by a computer controlled process called Filament Winding.

      • Alex Rhino

        Thank you! I really love this bike and learning about the process is really interesting! 3D printers have opened so many doors for design.

  • DominicBruysPorter

    Looks very BMC, in a good way. I think the dropouts are a might out of place though, they almost look like an afterthought compared to the elegance of the other joints.

    I’d ride it.