Production of Functional Prototypes of Professional Tools for Bicycle Mechanics

From Digital Design to Two Material Options Through Metal Additive Manufacturing

Drom.bike s.r.o., in collaboration with the D1 Industrial Design Studio at UMPRUM, developed a new range of hand tools for professional bicycle mechanics. For the next stage of development, the company needed to turn the digital designs into functional metal prototypes that could be used to validate both the design and material suitability under real-world conditions.

The tool set includes spoke pliers, a spoke wrench, and a spoke holder. Drom.bike approached Brain4Industry to produce functional prototypes using metal 3D printing. To compare the materials in practice, two complete sets were produced. One in stainless steel and the other in aluminium.

Brain4Industry Solution

The process began with a review of the supplied 3D models and technical drawings, followed by feedback on the necessary modifications. After the designs were updated, we carried out additive manufacturing of the metal components in both material variants.

After 3D printing, the functional areas were machined, particularly those with specified tolerances for the nylon bearings. This was followed by surface finishing, including sandblasting. The result was a set of functional prototypes ready for testing.

The current design was developed primarily for prototyping. If drom.bike decides to use additive manufacturing for larger production volumes, the geometry will be further optimized according to Design for Additive Manufacturing (DfAM) principles.

Key Project Challenges

• Compare stainless steel and aluminium within a single prototyping phase.
• Meet the specified tolerances of functional areas for the nylon bearings.
• Combine metal 3D printing with subsequent machining and surface finishing.
• Produce functional prototypes suitable for practical design validation.

Project Result

Two functional prototype sets of professional bicycle wheel-building tools were produced. One in stainless steel and one in aluminium.

Both variants are currently undergoing practical testing by drom.bike. The results will help compare their properties in real-world use and inform the choice of material and manufacturing technology for future production.

Benefits for the Client

• Functional metal prototypes ready for testing.

• The opportunity to compare two material options before moving to the next development stage.

• Validation of metal additive manufacturing as a potential production technology.

• Data to support decisions on material selection and the future manufacturing process.

Prototyping allows important decisions to be tested and validated during product development before the final manufacturing process is selected. For drom.bike, metal additive manufacturing provided a way to transform digital designs into functional prototypes and evaluate two material options within the same development phase.

The test results will now provide a basis for the next development decisions. If additive manufacturing is selected, the prototyping phase can be followed by further design optimization according to DfAM principles, adapting the geometry to the requirements of efficient series production.

Do you need to turn a new product from a digital design into a functional prototype and validate it before the next stage of development? Contact us and we’ll help you find the right approach.