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TE Connectivity built the world’s first functional, 3D-printed motorcycle in 2014 (as recognized by the Guinness World of Records). According to TE Connectivity, the 3D printing process involves programing a computer with the digital pattern for a unique product. This pattern dictates how strands of plastic will print together in layers. As layers print and overlap, they fuse together to form a single part, or motorcycle part in this case. Fun facts shared about the world’s first 3D-printed motorcycle, claim the bike reaches a whopping speed of 10-15 mph. Additionally, the bike weighs in at 250 pounds, measuring 8 feet long, which can support two adult riders. Further, the motorcycle is considered a hardtail design, featuring a frame, wheel bearings, handlebars and a seat, which are all printed in plastic.
According to Chuck Fry, the principal engineer on the 3D-printing team, “Additive manufacturing is the ability to take and create something by putting materials together. For example, the headlight was 3D printed and then it was finished, and then we added copper and then nickel plating on top of it.” According to Fry, “Everything was done in an additive fashion instead of the standard methods of manufacturing. In additive manufacturing, you add things to it rather than subtract.”
In the process, the team was determined to create a custom design that offered more freedom to create something new. Fry went on to say, “Starting with a custom design allowed us to display what additive manufacturing is all about. And that’s the ability to make custom features, custom designs. That type of customization is something that is easy in additive manufacturing and difficult in regular manufacturing. We decided to do this motorcycle because we wanted to…demonstrate the capabilities of additive manufacturing and 3D printing. We needed people to see what it was capable of. It can do things that can’t be done otherwise.”
In the US, additive technology is rapidly growing and being applied in the motorcycle industry. In Brooklyn, New York, Tarform Motorcycles is applying 3D-printing methods to the development of electric motorcycles. Tarform CEO, Taras Kravchouk, learned early in the attempts of prototyping a new breed of electric motorcycles, that innovations in the motorcycle manufacturing processes had not developed in over 100 years. With the goal of surpassing the status quo, Tarform adopted 3D-printing in the production of the Tarform Scrambler. In the development of Tarform Scrambler, “I wanted to revive the classic form, and unite it with modern day technology to create a new riding experience.” Kravchouk went on to say, “In my opinion there is a disconnect between current motorcycle design and what the younger generation finds appealing. Once we started to optimize our design for low volume manufacturing, the idea of using traditional methods did not make much sense, neither from an economic perspective, nor from a design perspective.” Moving forward in the development process Kravchouk explored with various methods of manufacturing, including applications of additive technology with 3D-printing, ultimately accomplishing a motorcycle by using sustainable materials and reducing waste. 3D-printing played a key role in the manufacturing process of Tarform Scrambler. “As I mentioned, the use of 3D printing allowed us to optimize parts due to the inherent rapid speed of prototyping and it gave us the opportunity to use a lot of sustainable materials in the manufacturing process,” said Kravchouk.
In addition to Tarform Motorcycles, Divergent, a US-based developer has created an end-to-end software-hardware solution that incorporates Nodes, or 3D printed metal connectors, with lightweight materials to design strong and efficient complex structures. Divergent has applied 3D printing technology in their Dagger motorcycle, which sits on a 3D-printed chassis. According to Divergent, the parts of the Dagger are what really make it special, although it looks incredible as well.
Although Dagger is not made completely from 3D-printed materials, the bike has pushed beyond traditional manufacturing methods to create something important for future applications. The 3D-printing applications allowed for 50 percent lighter than the traditional materials used in past production methods, resulting in a stronger end product with greater efficiency on the road, yet not impacting rider safety.
Divergent, located in Torrance, California, was founded in 2014 and continues to incorporate 3D metal printing into their designs, engineering, and manufacturing of advanced vehicle structures for the automotive and aerospace industries. The application of 3D printing in the motorcycle space is a new step for the company. The company’s proprietary system automates structural design and optimization for volume manufacturing of lightweight structures without upfront, capital-intensive factory, and tooling investments.
The Dagger bike is a first 3D-printed motorcycle for the company and its existence conveys a lot about the possibilities for the future. Divergent has produced a 3D-printed supercar by partnering with auto manufacturers such as PSA Groupe to make a mark in the industry. According to Kevin Czinger, Divergent’s CEO, the developments and applications of 3D technology will open up the supply chain to offer smaller companies a more diverse landscape for future development by lowering costs and increasing production speeds, which not only creates more diversity, but increased freedom in the possibilities for design.
Since 2022, 3D Concepts Moto has been printing motorcycle parts. The father and son team, including Stuart, Paul, and Andrew Connell, got their start in the 3D printing industry when Stuart bought his first printer. Because of his “do-it-myself” personality, he naturally started printing anything he could think of, including parts for their own motorcycles. After showing the cool stuff made for their own dirt bikes and getting a lot of interest from friends, family, and the local Treasure Valley community, 3D Concepts Moto began.
The father and son team is comprised of a retired construction and mining equipment engineer who used to race motocross, a car, truck, and motorcycle enthusiast, and a certified aircraft mechanic who loves to ride in the mountains. Together, we’ve been printing motorcycle parts for the past four years before starting 3D Concepts as a company.
Our motorcycle addiction goes back to the 1970s and 80s when father, Stuart, raced motocross in the Southwest part of the United States. Andrew and Paul’s first bikes were a Yamaha YZ-80 and a KTM 125SX. Andrew took to the dirt like a fish to water, while Paul’s interest peaked when he moved to Idaho in 2012, because of the amazing mountain single track.’’
The core values guiding 3D Concepts Moto’s vision stems from the application of custom parts on their own motorcycles. “We started making motorcycle parts for ourselves, because we wanted something better. Now we want to provide something better for our customers as well.”
The motivation behind 3D Concepts Moto’s vision is simple. We love to ride, and we love to build things! It’s our goal is to offer cost-effective, protection for critical off-road motorcycle parts for our customers. It’s these primary values that kick-started our business and is the fuel that motivates our success.
Phone: 903-647-4926
Email: [email protected]