Revolutionary Advantages: 3D-Printed Cycling Jerseys Optimized for MTB and Road Racing

3D-printed cycling jerseys promise a new era of sportswear tailored precisely to the specific needs of mountain bikers and road cyclists. Thanks to precise manufacturing, these jerseys offer not only a perfect fit but also elevate function and protection to an entirely new level.

For Mountain Bikers: Adaptive Protection

A mountain biking jersey that protects without getting in the way – that’s the vision of 3D printing. Flexible protective structures made from hexagonal elements can be integrated directly into the fabric. These honeycomb-like designs are highly efficient at absorbing impact energy (ideal for trail crashes) while offering excellent freedom of movement and breathability. Strategically placed at the shoulders, elbows, and back, they provide targeted protection where it matters most, all while being lighter and more comfortable than conventional protectors. The result is a second skin that protects and breathes with you.

For Road Cyclists: Aerodynamics That Save Seconds

In road racing, every millisecond counts. 3D-printed jerseys can make all the difference by minimizing air resistance. Fine surface textures or strategically placed guiding elements and fins can optimize airflow around the body. Much like the dimples on a golf ball, microscopic structures in the fabric influence the air in such a way that it clings longer to the body, reducing turbulence. The result is enhanced aerodynamics that help you reach the finish line faster. These invisible features are seamlessly integrated into the jersey, ensuring a perfect fit and helping you maximize performance with every pedal stroke.

A roller test bench based on DIN 79010 is available for testing complete vehicles. This allows the durability to be tested under controlled conditions with realistic operating loads in a short time. The drum diameter is 400 mm and the speed can be continuously adjusted from 0 to 45 km/h. The load is varied by differently designed impact bars. Vehicles with a wheelbase of 1 m to 2 m, a track width of up to 1 m (single or multi-track) and a maximum weight of 280 kg can be tested.

Individual parts and vehicle components can be tested using dynamic testing machines. Modular test frames made of aluminum profiles are used for positioning and fixing the test specimens. Thanks to the flexibly configurable test area, larger components such as wheels or complete bicycle frames can also be subjected to static and dynamic loads. The force is applied by one pneumatic and one electric cylinder. These can be used to apply forces of up to 7.5 kN, test frequencies of up to 10 Hz and strokes of up to 300 mm. The cylinders can be used both in single-axis operation and combined in multi-axis operation. In addition to testing in accordance with common test standards, individual test sequences and setups, tests using recreated measured signals and stiffness measurements are also possible.

Our innovative micromobility vehicle frame redefines sustainability by combining advanced materials and manufacturing techniques to create a lightweight, strong and environmentally friendly construction. The frame consists of UD tape-wrapped tubes attached to FLM-printed node elements, where bio-based reinforcement fibres such as flax and tubes made from bamboo can be used. The thermoplastics used for the frame can also be bio-based and fully recyclable to support a closed-loop circular economy.

Features of the frame:

- UD tape wrapped tubes: The main structure of the frame consists of tubes wrapped with UD tapes. These tapes are wound in an optimised arrangement to ensure maximum strength and rigidity. The use of bio-based reinforcing fibres such as flax offers an environmentally friendly alternative to conventional materials.

- FLM-printed node elements: The connection points of the frame are printed using fused layer modelling (FLM). These node elements are locally reinforced after printing to ensure optimal performance and durability. Localised reinforcement adds material where it is needed most, resulting in efficient use of resources. Thanks to 3D printing, the gusset elements can be customised to ensure optimal fit and functionality.

- Versatile choice of materials: In addition to the classic carbon and glass fibres, bio-based reinforcing fibres such as flax can also be used to strengthen the frame. In addition, bamboo tubes can be used as alternative structural elements. This versatile choice of materials makes it possible to minimise the environmental impact while achieving optimum performance.

- Environmentally friendly thermoplastics: The thermoplastics used for the frame can be bio-based and contribute to reducing the environmental impact. These materials are not only lightweight and durable, but also fully recyclable, which contributes to a closed-loop economy.

Areas of application:

Our sustainable frame is suitable for a wide range of micromobility vehicles, including electric bicycles, cargo bikes, electric scooters and pedelecs. It offers an ideal combination of lightness, strength and environmental compatibility, making it an attractive solution for urban transport.

Using the specially developed test bench for mid-mounted e-bike motors, it is possible to test the operational stability and the function of the control system at an early stage of development. In endurance tests, the mid-motor can be subjected to load collectives consisting of time-weighted speeds and torques, thus enabling the behavior of the motor to be observed under long-term load. The test bench is able to emulate a driver cadence of up to 150 rpm and a maximum crank torque of 300 Nm. All performance data of the mid-engine are measured.

Cargo bikes are one of the fastest-growing model groups on the e-bike market. The focus in the development of the drive is increasingly on combining the support motor, an automatic gearbox and a regenerative brake in one unit. By means of a V-belt CVT or combinations of planetary gear sets, new economical overall solutions are emerging that fulfill the aforementioned aspects in the form of a mid-motor. The concepts investigated provide for an adjustment range of over 400 %.

Revolutionary Advantages: 3D-Printed Cycling Jerseys Optimized for MTB and Road Racing

3D-printed cycling jerseys promise a new era of sportswear tailored precisely to the specific needs of mountain bikers and road cyclists. Thanks to precise manufacturing, these jerseys offer not only a perfect fit but also elevate function and protection to an entirely new level.

For Mountain Bikers: Adaptive Protection

A mountain biking jersey that protects without getting in the way – that’s the vision of 3D printing. Flexible protective structures made from hexagonal elements can be integrated directly into the fabric. These honeycomb-like designs are highly efficient at absorbing impact energy (ideal for trail crashes) while offering excellent freedom of movement and breathability. Strategically placed at the shoulders, elbows, and back, they provide targeted protection where it matters most, all while being lighter and more comfortable than conventional protectors. The result is a second skin that protects and breathes with you.

For Road Cyclists: Aerodynamics That Save Seconds

In road racing, every millisecond counts. 3D-printed jerseys can make all the difference by minimizing air resistance. Fine surface textures or strategically placed guiding elements and fins can optimize airflow around the body. Much like the dimples on a golf ball, microscopic structures in the fabric influence the air in such a way that it clings longer to the body, reducing turbulence. The result is enhanced aerodynamics that help you reach the finish line faster. These invisible features are seamlessly integrated into the jersey, ensuring a perfect fit and helping you maximize performance with every pedal stroke.

A roller test bench based on DIN 79010 is available for testing complete vehicles. This allows the durability to be tested under controlled conditions with realistic operating loads in a short time. The drum diameter is 400 mm and the speed can be continuously adjusted from 0 to 45 km/h. The load is varied by differently designed impact bars. Vehicles with a wheelbase of 1 m to 2 m, a track width of up to 1 m (single or multi-track) and a maximum weight of 280 kg can be tested.

Individual parts and vehicle components can be tested using dynamic testing machines. Modular test frames made of aluminum profiles are used for positioning and fixing the test specimens. Thanks to the flexibly configurable test area, larger components such as wheels or complete bicycle frames can also be subjected to static and dynamic loads. The force is applied by one pneumatic and one electric cylinder. These can be used to apply forces of up to 7.5 kN, test frequencies of up to 10 Hz and strokes of up to 300 mm. The cylinders can be used both in single-axis operation and combined in multi-axis operation. In addition to testing in accordance with common test standards, individual test sequences and setups, tests using recreated measured signals and stiffness measurements are also possible.

Our innovative micromobility vehicle frame redefines sustainability by combining advanced materials and manufacturing techniques to create a lightweight, strong and environmentally friendly construction. The frame consists of UD tape-wrapped tubes attached to FLM-printed node elements, where bio-based reinforcement fibres such as flax and tubes made from bamboo can be used. The thermoplastics used for the frame can also be bio-based and fully recyclable to support a closed-loop circular economy.

Features of the frame:

- UD tape wrapped tubes: The main structure of the frame consists of tubes wrapped with UD tapes. These tapes are wound in an optimised arrangement to ensure maximum strength and rigidity. The use of bio-based reinforcing fibres such as flax offers an environmentally friendly alternative to conventional materials.

- FLM-printed node elements: The connection points of the frame are printed using fused layer modelling (FLM). These node elements are locally reinforced after printing to ensure optimal performance and durability. Localised reinforcement adds material where it is needed most, resulting in efficient use of resources. Thanks to 3D printing, the gusset elements can be customised to ensure optimal fit and functionality.

- Versatile choice of materials: In addition to the classic carbon and glass fibres, bio-based reinforcing fibres such as flax can also be used to strengthen the frame. In addition, bamboo tubes can be used as alternative structural elements. This versatile choice of materials makes it possible to minimise the environmental impact while achieving optimum performance.

- Environmentally friendly thermoplastics: The thermoplastics used for the frame can be bio-based and contribute to reducing the environmental impact. These materials are not only lightweight and durable, but also fully recyclable, which contributes to a closed-loop economy.

Areas of application:

Our sustainable frame is suitable for a wide range of micromobility vehicles, including electric bicycles, cargo bikes, electric scooters and pedelecs. It offers an ideal combination of lightness, strength and environmental compatibility, making it an attractive solution for urban transport.