The e-bike from the 3D printer

3D printing in the development process

When developing an e-bike, we use 3D printing to be able to produce a tangible prototype as quickly as possible. This allows us to identify any errors and inaccuracies at an early stage and save time and resources in development.


Our partner

When manufacturing prototypes using 3D printing, we rely on an experienced specialist from Germany: Christian Schaab, Manager of ProDimensional in Grosskarolinenfeld, Bavaria (Germany).


“It takes three and a half days for a 50-centimeter frame component to be finished. The 3D printer uses a nozzle to apply the black plastic in 0.15 millimeter layers. This process is called melting,” explains Christian Schaab.


Website ProDimensional

Benefits of 3D printing

We use the prototype in 3D to check the design and function of a new model. In the past, prototypes were made from aluminum, which took much longer.


“The good thing about the 3D models is the precision, flexibility and speed at which we can then modify or rework products,” says Lars Tanner, Product Manager and Head of Test Mechanics at FLYER.


Find out here how the development process for a FLYER e-bike works.

Development process FLYER E-Bikes

The future of 3D printing

3D printing promises many new possibilities. At the moment, it is still very expensive to print entire bikes using an additive process. Individual components that can be produced in series, such as pedals, are available at a moderate price from a 3D printer.


In the future, 3D printing will be able to help reduce weight, speed up production time and, in some cases, reduce costs. In addition, 3D printing will allow bicycles to be more individualized.


Stefan Ruzas, editor of FOCUS E-Bike, monitors the market and confirms the trend towards 3D printing: “Two-time World Cycling Champion Filippo Ganna showed up at a road race with a 3D-printed steering cockpit on his racing bike that was precisely adapted to his wishes.”



FOCUS E-Bike visits FLYER in Huttwil

FOCUS E-Bike visited both ProDimensional in Grosskarolinenfeld and our factory in Huttwil and spoke to Lars Tanner, Product Manager at FLYER.

Read article (in German)