3D printing, or additive manufacturing, is reshaping the bicycle industry by enabling unprecedented levels of customization, lightweight design, and rapid innovation. From professional racing to everyday cycling, this technology allows manufacturers to create complex geometries impossible with traditional methods like welding or molding.
One of the biggest advantages is customization. Brands like Superstrata produce fully 3D-printed carbon fiber frames tailored to a rider’s exact measurements, improving fit, comfort, and performance. Similarly, companies such as Atherton Bikes and Moots use 3D-printed titanium lugs and dropouts bonded to carbon tubes, offering bespoke geometries for elite athletes.

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Lightweight and strong components are another key benefit. Titanium parts, printed via metal additive manufacturing, reduce weight significantly—Pinarello’s Bolide F HR 3D helped set hour records with its optimized frame. Mythos introduced the world’s first commercial 3D-printed stem, while Fizik and Carbon collaborate on custom saddles with lattice structures for better pressure distribution.

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Prototyping has accelerated development. Canyon uses large-format printers for full-scale mountain bike frames, enabling quick iterations with topology optimization for efficiency and sustainability. Urwahn and Hanglun integrate 3D-printed parts for integrated designs, reducing turbulence and enhancing aerodynamics.
Even accessories benefit: KAV‘s 3D-printed helmets and various custom grips or protectors show versatility. As costs drop and materials advance, from titanium to recycled composites, 3D printing promises more accessible, personalized, and eco-friendly bikes.
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In 2025, 3D printing isn’t just a novelty—it’s driving real-world performance gains, making cycling faster, more comfortable, and innovative than ever.

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Scientists at the University of Glasgow have successfully implemented an innovative new treatment for creating synthetic bones into a dog. The process is hoped to lead to human bone implants from a 3D printer.

The implantation was used to save the two-years old Munsterlander named Eva and the technology was funded by the Find a Better Way charity. Founded by Sir Bobby Charlton, Find a Better Way announced a £2.8m financial agreement with the University of Glasgow last year. The partnership was made with the aim of developing 3D printed limbs.

Giving the dog a bone

Eva’s front leg was broken during a car accident and since hasn’t been able to heal due to persistent infections requiring bone tissue to be removed. As a result, Eva was left with a 2 cm gap in her foreleg bone and was close to amputation. However, vet William Marshall discovered a possible treatment in the form of an untested technique developed at the University of Glasgow.

Using a protein known as BMP-2, the scientists were able to encourage bone growth but were not yet due to trial the method on humans for another few years.

William Marshall took the gamble and implanted a combination of BMP-2, a binding agent known as poly(ethyl acrylate) or PEA and bone chips and Eva’s bone marrow. As it was the first use of the technique, the results were unprecedented and seven weeks later Eva has made a full recovery.

Paving the way for synthetic 3D printed bones

Having demonstrated the potential with Eva’s implantation, the team at the University of Glasgow will use the procedure as a learning exercise for future 3D printed implantations.

The same BMP-2 process will be used in the future with 3D printed scaffolds and stem cells to treat landmine survivors in Cambodia. The technique works by using biomedical grade plastic which eventually dissolves to leave a newly-grown bone in its place. The 3D printing technology has potential not just for land mine victims but for promoting bone growth across the body. Sir Bobby Charlton describes the significance of the surprising development,

When I signed the funding agreement for this project just six months ago I was not expecting there to be any results from this technology for years. Eva is a beautiful dog and I’m delighted she will now have a normal life thanks to the work Find A Better Way has funded at the University of Glasgow. I’m even more thrilled to think about what promise this technique holds for landmine blast survivors, and the rest of humanity, in the future.

Californian company SI-BONE is similarly using 3D printing to promote bone growth with titanium implants. The company has just been granted FDA clearance.

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The research found a 3D printed structure was up to 85% stronger by mimicking the criss-crossed layers typically found in the shell. The researchers, Grace Gu, Mahdi Takaffoli, and McAfee Professor of Engineering Markus Buehler, believe the material has potential application for use in body armor.

The full article, titled ‘Hierarchically Enhanced Impact Resistance of Bioinspired Composites’, has been published in Advanced Materials.

Advanced toughness

To begin the project, the MIT researchers evaluated a conch shell for toughness properties. Toughness, in relation to materials, relates to its ability to absorb and dispel energy without fracturing. Upon analyzing a conch shell’s characteristics, the research team found its superior toughness was contained in the layers of alternating grains. This three-tiered structure, according to the paper, means cracks and fractures find it difficult to spread through the layers.

Gif shows the material 3D printing on a Stratasys machine. Images via MIT.

The researchers subsequently sought out to replicate this structure using a 3D printer. Once simulating the shell’s structure on a computer, the team used a Stratasys Objet 500 3D printer to create a material which simulated a conch’s multi-layer structure.

MIT researchers have turned to 3D printing in the past by using the technology to showcase the intricate geometry of graphene.

Gif shows impact testing using a Drop Tower. Images via MIT.

Drop Tower testing

In order to evaluate the toughness of the 3D printed conch-like material, with a base material comparison, the researchers used a Drop Tower. Performing impact tests using the Drop Tower showcased the multi-layered material’s ability to dispel energy with minimal cracking or fracturing. These tests showed the conch structure was 85% better at resisting impact and 70% better than a traditional carbon fiber arrangement which uses interlocking threads.

Researchers at McGill University in Canada have also demonstrated positive results by 3D printing ABS materials in a jigsaw shape.

Conch shell applications

MIT’s researchers believe the material developed has the potential to create advanced body armor or helmets. Particularly since the use of 3D printing can be complimented with the use of 3D scanning. For this reason, the researchers explain the possibility of creating individualized helmets or body armor which would have both the optimal fit for the user and have advanced properties due to the conch-like layers of the printed material.

Similarly, American football equipment manufacturer Riddell has announced it will use 3D scanning technology to create bespoke ‘Precision-Fit’ helmets. As reported, the use of 3D scanning hopes to improve fit and performance by reducing pockets of air inside a helmet.

Perhaps in the future, for added resistance, the manufacturer could incorporate the conch-like structure of MIT’s 3D printed material.

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The U.S Department of the Navy (DoN) has revealed plans to use a blockchain to control its 3D printers.

The U.S Navy is increasing its implementation of 3D printing and earlier this year ordered its first Concept Laser metal 3D printer and also recently produced its first 3D printed aircraft part.

Lieutenant Commander Jon McCarter has now revealed in a blog post that the DoN will begin trialling blockchain this summer before issuing a report in September on the proof-of-concept.

Decentralized network

Blockchain is an example of a decentralized network which means data is shared across the network and not secured in one location. By having a distributed network in this way the Navy can “both securely share data between Additive Manufacturing sites, as well as help secure the digital thread of design and production.”

The digital thread is the data concerned with manufacturing a part and is all the data that defines the manufactured part across its development – from design to final part production.

By outlining a component’s life in this way, the U.S Navy can assert greater security and control over the manufacturing process. Security is increasingly gaining attention within the 3D printing industry as the technology is used to make critical parts.

North Dakota State University’s (NDSU) Jeremy Straub explored this topic recently and outlined a process for enabling greater security during the printing process.

Why implement a blockchain system?

As the DoN advances its manufacturing supply chain with 3D printing, allowing it to be faster and closer to deployed forces, this simultaneously opens the door to a new attack vector.

This heightens “the need for a cryptographically secure, traceable, immutable, and controllable data flow.” The DoN’s LCDN Jon McCarter believes blockchain and Naval additive manufacturing are a perfect match since,

The ability to secure and securely share data throughout the manufacturing process (from design, prototyping, testing, production, and ultimately disposal) is critical to Additive Manufacturing and will form the foundation for future advanced manufacturing initiatives.

Demonstrating this, the U.S DoN recently held a 3D Print-a-Thon at the Pentagon in which 40 different Navy and Marine projects presented their innovative use of the technology.

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The ultrasonic 3D printing technology was demonstrated by the company’s Ultrasound Research Group and has particular potential for electronics. Research engineer and project lead for Neurotechnology’s Ultrasound Research Group, Dr. Osvaldas Putkis explains the patent-pending 3D printer will use a variety of materials in order to produce electronic objects that are entirely 3D printed.

Putkis says the 3D printer is “capable of printing virtually anything” and points to the example of a smartphone with all its components printed from a single device.

Gif shows suspension of small material using ultrasonic transducers. Images via Neurotechnology.

Ultrasonic transducers

Using ultrasonic transducers, the research group manipulated small materials and even electrical components to a high degree of accuracy. The prototype device can transport electronic components to a specific location and then solder them with a laser. The process is enabled by a camera which determines the position of the substrate and materials.

Ultrasonic technology has been used for 3D printing prior to this with Ohio-based company Fabrisonic. However, Fabrisonic’s patented technology uses ultrasonic sound waves to weld thin layers of metal sheets together. The company was recently granted a new patent to incorporate the technique into hybrid machinery.

Gif shows the manipulation of foam material. Images via Neurotechnology.

Materials and components

Dr. Osvaldas Putkis, who is listed as the inventor of the technology, explains the potential,

Ultrasonic manipulation can handle a very large range of different materials, including metals, plastics and even liquids. Not only can it manipulate material particles, it can also handle components of various shapes. Other non-contact methods, like the ones based on magnetic or electrostatic forces, can’t offer such versatility.

The non-contact nature, combined with high accuracy, means the system can control very small and sensitive particles without damaging them or affecting their electrostatic forces. The scale of component sizes can be from a number of millimeters down to sub-millimeters. Similarlly, we’ve seen how 3D printing has been used to create a tractor beam device that can suspend materials with transducers housed in a 3D printed cup.

Non-contact printing

By offering such versatility, Neurotechnology intends to develop a unique 3D printer device which could 3D print a wide range of materials and possibly allow for the creation of 3D printed objects with embedded components and electronics.

According to Neurotechnology, the Lithuanian company is currently inviting other organizations to support development of the project and ultrasonic particle manipulation technology.

If you’d like to 3D print your own acoustic tractor beam then you can download the files here.

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With many companies within the 3D printing industry looking at how to advance their machines for mass manufacturing, Blackbelt has a novel approach of bringing the conveyor belt to the 3D printer. 3D printing bureau Voodoo Manufacturing has similarly had this brainwave recently as it has incorporated a robotic arm and conveyor belt to automate its 3D printer factory.

3D printing of “endless length”
The Blackbelt 3D printer houses its 3 print heads on an X-Y actuation system, with the Z-axis in the form of a conveyor belt. This allows for theoretically infinite sized horizontal parts. The idea of infinite size is something Stratasys is addressing with its Infinite Build 3D printer. The device is currently undergoing testing at Ford Motors.

Continuous printing
Not only does the machine’s conveyor belt enable endless horizontal size, its functionality as a moving print bed allows for continuous printing. The printer can hold a container, as shown, that can collect finished parts enabling the machine to keep running.
This function is appropriate for series production since Blackbelt claims it is “not necessary to remove the prints manually.” Blackbelt believe this is enabled because the conveyor belt is made from “carefully selected and well tested carbon fiber composite.”


Support free overhangs
Due to the X-Y actuation system’s print angle it is possible to print support-free overhangs. The machine is by default set to print at 45° but this can be adjusted to be lower at 15°, 25° or 34°. However, Blackbelt do explain that some prints may require a starting geometry in order to do this, as shown.


Large format printing
As mentioned earlier, the conveyor belt allows for endless length and the ability to create large-scale printed parts is a major benefit of the device. In order to facilitate this, Blackbelt have incorporated a roller table for support. The company explains that, “for prints of 1300mm or longer, we recommend using the roller table to provide additional support while the printing process.”
The Blackbelt 3D printer will release in two formats, a desktop version and a stand-alone version which includes standing frame and roller table to realize the large-scale possibilities of the device.

Specifications
– Interchangeable print heads
– Industrial linear guides
– Building volume: 340 x 340 x ∞ mm (13” x 13”x ∞”)
– Print angle adjustable: 15°/ 25°/ 34°/ 45° – 45° by default, some parts come out better at lower angles.
– Filament diameter: 1.75mm
– Print heads: nozzle sizes 0.4/ 0.6/ 0.8 mm come with the printer. Further sizes will be available.
– Retail price: 9,500 EUR Desktop version. 12,500 EUR with standing frame and roller table
The Blackbelt 3D printer will launch on Kickstarter, with further details expected to be announced on Friday May 12th.

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Michael Petch from 3D Printing Industry

In a research article published today by Science Robotics, work by Massachusetts Institute of Technology’s (MIT’s) Mediated Matter lab in Cambridge describes a 3D printing method for the construction of large structures.
A robot arm, mounted on a vehicle, controls a nozzle through which an expanding foam is sprayed. With repeated passes, a series of layers of the foam are built up. As the foam expands, it sets and the cavity created by building two parallel walls can then be filled with concrete. The case study shows how an architectural-scale hemi-ellipsodial dome section was 3D printed.

A variety of fast-curing polyurethane foams were evaluated by the team, and Dow Chemical’s Froth-Pak insulation foam was used for the documented test print, “on the basis of cure rate, ease of spray control, and consistency of layer deposition.”
The Digital Construction Platform
The researchers call this the Digital Construction Platform (DCP), “an automated construction system capable of customized on-site fabrication of architectural-scale structures using real-time environmental data for process control.” The version presented in the research is the second iteration of the platform and uses, “a 2015 Altec AT40GW aerial lift system, with a KUKA AGILUS KR 10 R1100 sixx WP electric robotic arm mounted at the aerial lift’s endpoint.”

A video shows the DCP 3D printer successfully printing a 14.6-m-diameter, 3.7-m-tall open dome formwork structure, that the researchers say was completed in less than 13.5 hours. Science Mag say this is the, “world’s biggest botmade building.” Able to extend 10 meters, the DCP has a load capacity of 158 kg.

Laser increases stability
Reportedly, the MIT team has received interest from Google, NASA and even a private individual who was interested to learn if the DCP could be used to create an underground basket ball court.
One of the key features that enables the DCP to operate in a precise manner is the inclusion of a laser on of the tip of the robot arm. The laser measures the arms position accurately and feeds back this information to allow for automatic adjustments to be made, and keeps the print run stable.
The DCP, “consists of combined hydraulic and electric robotic arms in a micro-macro manipulator configuration, mounted on a tracked mobile base.” Further details explain how the concept is based, “around a mobile compound robotic arm system composed of a large, 4-DOF hydraulic arm with a smaller, 6-DOF electric arm attached at its endpoint.” This set-up is similar in design to a human shoulder and hand say the researchers.

Self-sufficient operation
The project was led by mechanical engineer Stephen Keating who has grand ambitions for the DCP. Speaking to Science Mag, Keating explained that the 3D printer could be used to make a variety of unusual shaped buildings, “Instead of making a square building you can make a Dr. Seuss–looking building for the same cost.”
Off-world construction options may also be a future direction for the research. Equipped with solar panels and batteries, the Digital Construction Platform is designed to work in a variety of environments in a self-sufficient manner. The researchers conclude, “We believe that this is just the beginning of a new intermixed age of robotics, fabrication, and self-sufficiency.”
The article, “Toward site-specific and self-sufficient robotic fabrication on architectural scales” by Steven J. Keating, Julian C. Leland, Levi Cai and Neri Oxman can be read here.

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Corey Clarke from 3D Printing Industry
French researchers from Grenoble Alpes University have evaluated the environmental impact of 3D printing with a case study focused on the production of orthotic insoles.

The paper, available here, was presented as part of the 12th International Congress of Industrial Engineering. The researchers assessed the production of orthotic insoles with a conventional method in compared to the method used by a 3D printing startup company.

Life Cycle Assessment
To understand the environmental impact of the two processes, the researchers undertook a life cycle assessment (LCA). An LCA is a technique to analyze the environmental impacts of a product through all stages of its life, from raw material extraction to it’s final disposal or recycling.
Through the comparison, the researchers found that,

In Human Health and Climate Change, a 3D-printed insole is about 20% and 25% less impactful respectively. In Resources category, 3D Printed insole overcomes by 35% the impacts of a classic insole.

Relating to materials, the team report the “impacts from 3D printed insole are 65% less than a classic one in the four impact categories.” The four impact categories are Human Health, Ecosystem Quality, Climate Change and Resources.

Results of the LCA
Concluding the research, the team states the 3D printing process “impacts less than a Classic manufacturing considering Material, Distribution, and Usage phases.” While the two processes have similar end of life phases, “in the Production phase, the impacts of 3d-printing manufacturing overcome the other one.”
The research team notes that the length of time the insole takes to print is a considerable factor in relation to environmental impact, and one that varies drastically regarding the 3D printer that is used. The paper notes therefore that, “the way to reduce the environmental impacts of AM for this type of use is reducing the printing time investing in better performance 3D printers and choosing the best energy source.” The paper concludes that the 3D printing process itself is the most environmentally impacting element.

3D printed footwear
The 3D printing of footwear is a growing market and there are a number of companies exploring the industry, including Carbon who have most recently collaborated with sportswear manufacturer Adidas to produce 3D printed midsoles.
While elsewhere, Canadian 3D printing startup, Wiivv has developed the process of 3D printing insoles with proprietary software. The company raised over $500,000 in its latest kickstarter campaign for 3D printed sandals.
The research was carried out by Kléber Da Silva Barros, (Phd Student) Akhmal Ikhan Mansur, (Master Student) and Peggy Zwolinski, (Professor). The full paper can be read here.

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“Previous 3D printed designs have been mostly conceptual pieces that are solid, with little or no movement. We have strived to create stylish 3D printed garments that have sufficient movement to ensure they are fluid, eye-catching and comfortable to wear. These prototypes are made, dyed and finished by hand and our aim now is to produce them for a wider market,” says Dr Borstrock. “It will only be a matter of time before we see 3D collections on the high street and 3D printing technology in stores as part of everyday life. We’re pleased to be part of the movement that is exploring how this might become a reality.”

Movement in the material indeed plays a central role as you watch the video below, ‘Molly Makes a Dress,’ along with striking fabric, coloration, and overall design. The prototype line consists of eight dresses and two headpieces which can be customized. Size and shape can, uniquely, even be fitted after 3D printing as the ‘links’ in the material can be taken out or expanded manually. And if you are wondering about color after seeing the video, the materials can be dyed in virtually any color or shade.

“I’ve spent the last 25 years exploring how technology and 3D printing can enhance production techniques for jewellery and accessories, and this has been a fantastic opportunity to take this research even further. There is a huge amount of potential to develop complex construction techniques that defy traditional pattern cutting and create garments that are multi-functional, customisable and wearable,” said Professor Mark Bloomfield, Managing Director of electrobloom.

If you are interested in seeing more of this modeclix collection, mark your calendar as you can view it online beginning on May 1st. You can also actually see the pieces at the electrobloom store in London (Studio 2.11 , Oxo Tower Wharf, Bargehouse Street) from May 23rd on.
Work like this indicates a very positive evolution for the fashion industry, allowing for the individual to look forward to one-of-a-kind pieces without having to travel to design houses in Paris and spend exorbitant amounts that ‘regular people’ simply don’t have for the clothing budget. With 3D printing and progress in materials sciences, consumers can look forward to fashion-forward clothes that will be of much higher quality, better fit—and hopefully, with a much more attractive price-tag too. Discuss in the Modeclix 3D Printed Dresses forum over at 3DPB.com.

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