Milpitas, CA – April 8, 2020
 – two Silicon Valley company redefining global composites manufacturing through digitalization, today announced this technical partnership to deliver the world’s first 3D printed, continuous carbon fiber single-piece unibody frame for a new line of bicycle wheels and parts will sell under the “SPAZIALE” brand and e-Bikes, Road and MTB under ZEROUNO Bikes brand. Together to Manufacture World’s First 3D-Printed Carbon Fiber Unibody Bike Frames. 


AREVO AM 3D printing technology is unique in the additive manufacturing (AM) world as it features patented software algorithms enabling generative design techniques, free-motion robotics for “True 3D” construction, and direct energy deposition for virtually void free construction all optimized for anisotropic composite materials.

Further a unibody bike frame construction uniquely enabled, is setting a new benchmark in high-performance bikes. The ZEROUNO frame is made as a single part, in contrast to current composite frames, which are made of many parts glued together. With AREVO AM 3D Printing intelligent continuous carbon fiber placement, unprecedented structural integrity and stability are achieved.

The frames and new wheel-sets are in production now at AREVO’s new multi-purpose facility in North California where both companies facilities are located.

This achievement with the new MAG SL first prototype represents several breakthroughs for bicycle manufacturers, with implications for other frames as well. Starting with a nylon prototype, to actually create the first carbon finder printed prototype by mid May. The model year 21 of the new MAG will have some parts made in 3D printing, but not the whole frame for now. The whole MAG SL 3D printed frame will be tested for the next 6/8 months by ZEROUNO team before be considered to actually distribute it to the general public.

One of the key components of the system is also a software-based, real-time engineering design tool that can evaluate the load and stress factors to be applied to a given product. The system can take into account the pressures generated by weight and motion. It can calculate visually on-screen, torsional stress and rigidity, as well as joint stress points of a given part. Matching this CAD-based simulation with their ability to use the five-axis print head allowed ZEROUNO to develop a layering method that inserts strands of carbon fiber in the proper direction to address the needs of the design as it builds the finished product. Unlike traditional matte layers of the substrate, this method makes the finished product stronger, lighter in weight and perform better under use loads.

Stay tuned for lots more to come.


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