Berria Bike and Mausa 3D Unveil 3D-Printed E-Bike Prototype
The use of additive manufacturing as a tool for developing and testing new products has become increasingly more popular within high-demand and well-established industrial sectors. Recently, much of this new testing has been used within the bicycle sector. More specifically, in high-performance cycling, Berria Bike and Mausa 3D are showcasing the benefits of prototyping. These companies are jointly developing the first e-bike prototype that is produced through 3D printing.
The main goal of the collaboration was to bring the design of the new ‘Mistral’ model to life. The new model is an e-road and gravel bike known for its lightweight construction and performance across varied terrains. The prototype has allowed the team to test the bike’s geometry, component integration, and ergonomics before moving on to the industrial production of the final frame.
The e-bike frame made from PA12. (Credit: Mausa 3D)
Using a Multi Jet Fusion process, the Mausa 3D team was able to produce a functional prototype in just 3 to 4 days. This approach allowed Berria Bike engineers to analyze the geometry, validate the component integration, and make design adjustments without relying on costly molds or lengthy production cycles. The prototype, made from PA12, boasts precision of up to 0.1 mm, ensuring quick and seamless assembly. Moreover, 3D printing removed design constraints, giving full freedom to optimize shapes and structures before moving to final production.
Mausa 3D handled the preparation and subdivision of the model for printing, carried out in-house manufacturing, and completed the full assembly of the prototype. The result was a fully functional prototype with tolerances within the intended design range. The final e-bike frame was produced in full HM2X carbon fiber and features an ICS2 internal cable routing system. The bike is now available for purchase, with models ranging from €4,500 to €8,000.
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*Cover Photo Credit: Berria Bike
