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The Revel Rodeo is in a class of 1, by and thru.
It’s the first-ever bike with a totally 3D-printed carbon fiber downhill body that’s viable. The results of what the model calls a “ardour mission,” the one-off idea sucked up some analysis and design sources on its option to existence.
It’s additionally a looker.
“Whereas purely an idea bike and never presently on the market, the Rodeo exists as a groundbreaking instance of what is feasible with trendy additive manufacturing,” the corporate mentioned in a press launch.
With time, Revel is satisfied the manufacturing and supplies decisions it used for the bike might change the carbon bike panorama. Prices could also be excessive now, however at scale, 3D printing with fiber utilizing thermoplastic bonding brokers could possibly be extra environment friendly and environment-friendly.
How the Rodeo Turned Actuality
The Rodeo’s synthesis got here from a collaboration between execs in a number of industries. Revel Bikes Senior Engineer Jordan Haffener labored alongside the inventor of CBF suspension and skilled 3D printing producer Arevo Inc. to get the job finished.
And after I say skilled, I imply skilled. Arevo Inc. introduced the world a few of its first-ever 3D-printed composite bikes a number of years in the past.
Revel realized {that a} 3D-printed full-suspension MTB body in carbon was doable because of an earlier collaboration with FusionFiber. Revel RW30 wheels onboarded the forward-thinking carbon expertise in 2020. In rudiment, FusionFiber seems to chop down on steps and subtract vitality consumption from the normal carbon fiber manufacturing course of.
Most carbon (or composite) bikes use thermoset as a bonding agent. The epoxy is time-consuming to work with, and it makes the ensuing materials all however unrecyclable. FusionFiber is a thermoplastic, which suggests recycling bikes made with it could possibly be viable sooner or later. And since FusionFiber automates a number of fabrication processes, it’s quicker to work with, and fewer hazardous to anybody working with it.
The epoxy-less materials helped Haffener and the Rodeo’s design group sync up with Arevo Inc.’s additive manufacturing processes. After “dozens” of prototypes, they lastly landed on a winner and the Rodeo was born.
Manufacturing Outlook
The Rodeo gained’t hit cabinets, and its manufacturing descendants seemingly gained’t for fairly a while. However Revel nonetheless needed to provide a troublesome unit that would maintain its personal on rides. That’s as a result of it thinks the potential effectivity of the manufacturing could lead on others to undertake it on a big scale.
“Designing a downhill bike is without doubt one of the most formidable undertakings for any model as a result of they expertise abuse not like every other, from large drops, high-speed G-outs, and lateral stress from aggressive cornering; they demand sturdiness and reliability to resist seasons of using,” the model mentioned within the press launch.
“It’s arduous to not get excited in regards to the prospect of a 3D-printed carbon bike made right here in the USA. And the ramifications might imply extremely improved prototyping and growth processes for bike manufacturers, safer situations in manufacturing amenities, important environmental advantages, and larger customization for the rider at higher prices.”
Know-how and implementation each have to catch up earlier than Revel can carry the plenty the Rodeo (or one thing prefer it). However as wider adoption happens, that risk “turns into very actual,” the corporate mentioned. That’s partly the case as a result of it stands the prospect to decrease the brink for early-stage bike corporations trying to stand out with new designs.
And much from sequestering the expertise for its personal benefit, the corporate want to see it unfold.
“Our engineering group can mannequin up a motorbike in Solidworks, ship it to the printer, and have a totally useful carbon prototype in a matter of days. That is additionally a lot more cost effective, and customarily quicker, than many alloy prototype bikes, so it might assist smaller corporations out much more,” Revel Founder and CEO Adam Miller mentioned in an e mail.
“Iterations and concepts all of a sudden turn into cheaper to check out, which routinely results in extra innovation and higher bikes. Enterprise does get in the best way of bikes generally, and my purpose right here could be to take away as many limitations as doable to getting inventive and developing with the best concepts we are able to for bikes just like the Rodeo.”
Journey ’em, cowboys.
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