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.

[znicho]

Interesting that this has come out the same day Bastion's bars failed catastrophically during the Olympics.

[sc]

Bastion is probably the single most interesting bicycle company to date ;D

[WowRixter]

Despite what happened at the Olympics, that was still a remarkably interesting video. More like this please

[gowenu]

Before commentating on the timing, there are always other mechanical reasons for failure, overtightened screws etc. Let's wait until thorough investigation.

[global_nomad.]

been following Bastion for. a few years and waiting for the time when i can get one of their bikes....

[lucyparsons]

Talk about bad timing, not sure if Alex Porter will be an advocate for this tech (horrific handlebar failure Tokyo 2020).

[nguyenho]

Yall really posted this video at the right time

[patrickparisienne]

If I were to buy a “once in a lifetime” boutique bike, it would be a Bastion, no doubt. Shame about their public bar failure, but I’m sure they’ll learn from it.

[richardhaselwood]

Really enjoyed that one. Bastion do make some lovely bikes.
More importantly, they actually seem to employ some competent engineers, unlike most of the bike industry
Also, good public statement about the failure of one of their components on the Aus track team bikes (ie. We need to get the bottom of it)

[CG-]

Shame about the pursuit base bars they made for the Ozzie track team…….the catastrophic failure of the base bar on day one of the Olympic track program is not a good ad for Bastion at all.

[chrisvanbuggenum]

I don't know. Using lugs seems like old ideas with moderns technology. Despite that i still thought some of them looked gorgeous, but i went on the website and was blown away by the cost. I would never pay more than the cost of a Tarmac SL7 which is 18k AUD, which is heaps.

[PInkW]

As each of our builds are bespoke to their owner, price is upon application, however most Crossroad customers spend in the vicinity of AUD 25, 000

[davidpinnington]

Ah timing - saw a Bastion when i worked in Dubai 2-3 years back after fist becoming aware via Pinterest- works of art and some serious investment - wattshop mentioned elsewhere on here subcontracts out their printing as they did with the previous aerobars (got a set of their carbon version) - lugs/nodes etc - perfectly normal for engineering and construction and for cycles Atherton follow a similar process I think - come the time for my one road/gravel/grail bikes Bastion is on my list

[recyclespinning]

So des the Bond to carbon fiber come loose? Start your explanation by why this method is better?

[STIXEY]

Where were the Q.A. protocols?? - on the post Polishing of the the answer is??

[hotcakes]

I know they mentioned size restrictions and the time would be an age but id love to see a full frame built up just from the Ti dust to full frame

[tonychopper]

Is this the guy who USED to work for Bastion cycle? Have they accepted it was a bad idea.

[eijiroinouye]

I have a Litespeed Ultimate Gravel frame. Is it still a nice frame or is it now older technology?

[ancogbernard]

wish they will build bike that fully titanium

[LegSpinna]

Not the best time to talk about 3D printing in cycling!