Pivot Cycles combines carbon and 3D-printed titanium in the new bicycle prototype

Additive manufacturing On the way to a new frame concept through 3D printing

2025-03-19 Source: Pivot Cycles | Translated by AI 2 min Reading Time

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The bike manufacturer Pivot Cycles has combined carbon tubes with aluminum connectors in its prototype for the new generation of the Pivot Phoenix Downhill Special. With this prototype, the company has developed a frame that contains both carbon and 3D-printed titanium components.

In the prototype of its Pivot Phoenix Downhill Special, Pivot Cycles has replaced conventional aluminum lugs with 3D-printed titanium parts.(Image: Pivot) — In the prototype of its Pivot Phoenix Downhill Special, Pivot Cycles has replaced conventional aluminum lugs with 3D-printed titanium parts.
(Image: Pivot)

Additive manufacturing is becoming increasingly popular in bicycle production as it offers new design possibilities and allows the production of complex parts that are difficult to produce using conventional methods. Pivot Cycles also uses 3D printing in its Pivot Phoenix Downhill Specials.

The bicycle is characterized primarily by its structure and its dual-chain drive system. The conventional aluminum lugs have been replaced by 3D-printed titanium parts, a process similar to that used by Atherom Bikes or Möve Mobility. Möve combined its VER-TEC technology with 3D-printed titanium collars and hydroformed titanium tubes to create a durable frame. The pedal axle area is divided into sleeve segments weighing 133 grams, which are 3D printed and then bonded with the high-quality tubes. This method guarantees precise production, making the titanium frame not only functional but also suitable for mass production.

Gallery

The advantages of 3D printing in the production of titanium sleeves lie primarily in the ability to create complex designs and shapes.(Image: Pivot)

In the in-house R&D lab, the aluminum components are CNC-milled and the carbon tubes are produced.(Image: Pivot)

Although the prototype from Pivot is functional, it primarily serves to further explore this new manufacturing method. The company has an R&D lab where the aluminum components are CNC-milled and the carbon tubes are produced in-house. The titanium sleeves, however, were originally manufactured by an external provider using 3D printing.

Titanium for thinner-walled constructions

The advantages of 3D printing in the production of titanium sleeves lie mainly in the ability to create complex designs and shapes. Titanium was chosen for its robustness, which allows for thinner-walled constructions. Additionally, 3D printing offers more freedom in the complexity and form of titanium sleeves compared to the lighter metal aluminum. This results in the titanium sleeves of the Phoenix prototype being thinner, and the design in the bottom bracket area was crafted to resemble that of the standard carbon bike.

Chris Cocalis, CEO of Pivot Cycles, explains: "The sleeves are impressive, but we are most proud of the development and manufacturing process of the carbon tubes. This allows us to create the specific shapes required for production while experimenting with different materials and structures to improve the ride feel and overall performance of the chassis."

Pivot points out that the weight of the prototype has not yet been optimized, which means there is no significant weight difference between the two bikes. For future projects where weight is a more crucial factor, the titanium parts could be designed to be 15-20% lighter than those made of aluminum. Currently, mass production is not planned due to the excessive costs. The company estimates the investment for the Phoenix-Ti/Carbon frame project at $15,000 to $20,000. Chris Cocalis emphasizes that if series models were produced with this design and only minimal adjustments were made, the costs could be reduced but would still be two to three times higher than a conventional series frame.

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