How to 3D-print titanium with Bastion Cycles

Modern technology is continually opening the doors wider to new ideas. Metal hydroforming, computer-controlled milling and laser cutting are all now commonplace within bicycle parts manufacturing. And while still niche in the applied applications, you can add 3D printing to the list.

When it comes to 3D printing metal for bicycle purposes, few have more hands-on experience than the Melbourne-based team of Bastion Cycles. The team first used 3D printed titanium lugs in 2015 to produce the first custom road bike of its kind and continues to refine the technology today. For the past three years, the young Australian company has relied on in-house printing capabilities.

Bastion uses its 3D metal printers to produce the titanium lugs that dictate the custom geometry and stiffness of its carbon tubed bicycles, and as of this year, they’re now producing their own forks and cockpits, too. The company also produces frame components for renowned Australian custom builders such as Prova Cycles, Baum Cycles, Devlin, Mooro, and more.

So what exactly is 3D printed metal? What are the processes? And what are the limitations? For all of this, we sat down with Bastion’s Co-founder and engineering director – James Woolcock.

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