On August 11, 2023, the German company Core Technologie GmbH used 3D printing technology to manufacture a bicycle that managed to rank among the lightest bicycles without exceeding the minimum weight of the Tour de France. The bike uses a simpler, more automated modular manufacturing process, pairing 3D printed aluminum connector hubs with carbon fiber tubing.
It is reported that Core Technologie used its computer-aided design (CAD) and 3D printing software to transform the bicycle from a concept design to a product prototype in two months. The bike is assembled in the form of carbon fiber tubes + 3D printed aluminum connectors.
Core uses 3D-printed aluminum connectors around the nose, chassis, seat and chainstays to connect carbon fiber tubes supplied by German company Carbonforce. Core's design philosophy was also to create a high-performance two-wheeler that was simpler and more affordable than a traditional carbon fiber frame. Also, the process is less dependent on the supply chain.
The entire bike weighs just 7.1kg, which is reminiscent of the 6.8kg (15lb) minimum racing weight limit imposed by the International Cycling Union (UCI). In fact, the 11 bikes for the 2023 Tour de France were weighed and found to average just under 7.5kg, so Core can confidently say its bikes are lighter than those in the Tour de France .
The bike is also designed to accommodate a set of gears, so it's easy to change from a single speed to a variable speed bike. The bike is said to be a joy to ride and puts smiles on the faces of everyone who has tested it.
