In a recent breakthrough, the renowned 3D printing material supplier colorFabb has unveiled a new high-performance 3D printed wire called XT-CF20. This carbon fiber composite is based on a copolyester matrix and contains over 20% carbon fiber content. The result is a material that offers exceptional rigidity, dimensional stability, and heat resistance—making it ideal for demanding applications.
To showcase the potential of 3D printed materials, the colorFabb team took an innovative approach by using a standard desktop 3D printer along with XT-CF20 to create a fully functional bicycle. While the frame, wheels, and transmission system were mostly 3D printed, some components were still manufactured traditionally to ensure reliability and performance.
The design process began with SOLIDWORKS, where the entire bike was modeled in detail. The final parts were then printed using an Ultimaker Original Plus. After assembly, an intern from the design team, Stephen Schürmann, tested the bike by riding it through the town, proving its real-world usability.
“This concept bike demonstrates that a racing bike can be built using a common 3D printer and advanced composite materials,†the colorFabb team explained. “Our goal was to create a practical, everyday-use bicycle that shows engineers what modern 3D printing can achieve.â€
The XT-CF20 material was specifically chosen for its excellent stiffness-to-elongation ratio, making it perfect for structural components. The bike met all the weight requirements for competitive cycling and featured a strong, durable frame. The project focused on 3D printing parts capable of handling mechanical loads, though not every single component was 3D printed—some connectors were made using tubing and other materials.
For those interested in trying this themselves, the colorFabb team recommends using alternative materials like carbon fiber, titanium, aluminum, or even bamboo. Most mainstream 3D printers, such as MakerBot or Ultimaker, can produce the necessary parts. The team also conducted finite element analysis to validate the design and confirmed the bike’s functionality through real-world testing.
“This marks a new era in personal manufacturing,†said Schürmann. “With just basic SOLIDWORKS skills, anyone can design and 3D print their own custom bike frame. There are already many free design files available online, making it easier than ever to get started.â€
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