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3D Print Full Scale Bicycle

Passion for Cycling + 3D Printing

Each year, Sea Otter Classic takes place in Monterey, California—not far from Fathom’s Oakland Production Center. The event celebrates the cycling community with dozens of races and one of the largest consumer bike expositions in the world, earning it the unofficial title of the sport’s North American season opener. Happy to combine a love for cycling with a passion for additive manufacturing and advanced technologies, Fathom developed, 3D printed and assembled a full-scale bicycle to share with crowds on the sunny coast. Sea Otter was not the beginning of the Fathom’s cycling interest. In fact, several members of the team bike to work and the entire tooling department is passionate about cycling culture. Many of our customers, too! After reveling in the completed, 3D printed bicycle, a handful of Fathomers spoke to the importance of 3D printing in the cycling world.


From custom grips and inflatable frames, to lighter and stronger parts, Phil Stob, Derek Roedel and Sam Pirahanchi elaborated on the exciting future of additive manufacturing in cycling. Watch the video for footage of the 3D printed bicycle and hear what these members of the tooling team had to say. To learn more about Fathom’s 3D printing services (FDM, PolyJet, SLS and DMLS), start a conversation with an account manager.

Direct metal laser sintering is a great additive manufacturing technology for bicycles because weight is of great concern—bikes need to be lighter and stronger, said Roedel, Tooling Project Manager at Fathom. Plus, designers and engineers can take advantage of the design freedom to create customized bikes with really cool aesthetics. Cycling component manufacturers can think differently about how bicycles are designed by developing unconventional dropouts, hubs and frames with innovative patterns while making the parts lighter—retain or even increase the strength in aluminum steel or titanium parts, too.”

Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day

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30 Second Quotes
Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks

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3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

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Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

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Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

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CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

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Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

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Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.