How to 3D-print titanium with Bastion Cycles

Modern technology is continually opening the doors wider to new ideas. Metal hydroforming, computer-controlled milling and laser cutting are all now commonplace within bicycle parts manufacturing. And while still niche in the applied applications, you can add 3D printing to the list.
When it comes to 3D printing metal for bicycle purposes, few have more hands-on experience than the Melbourne-based team of Bastion Cycles. The team first used 3D printed titanium lugs in 2015 to produce the first custom road bike of its kind and continues to refine the technology today. For the past three years, the young Australian company has relied on in-house printing capabilities.
Bastion uses its 3D metal printers to produce the titanium lugs that dictate the custom geometry and stiffness of its carbon tubed bicycles, and as of this year, they’re now producing their own forks and cockpits, too. The company also produces frame components for renowned Australian custom builders such as Prova Cycles, Baum Cycles, Devlin, Mooro, and more.
So what exactly is 3D printed metal? What are the processes? And what are the limitations? For all of this, we sat down with Bastion’s Co-founder and engineering director - James Woolcock.
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[@znicho]

Interesting that this has come out the same day Bastion's bars failed catastrophically during the Olympics.

[@lucyparsons5799]

Talk about bad timing, not sure if Alex Porter will be an advocate for this tech (horrific handlebar failure Tokyo 2020).

[@LegSpinna]

Not the best time to talk about 3D printing in cycling!

[@RudiDwiHartanto]

this is one of thoee big oof moment

[@CG-99]

Shame about the pursuit base bars they made for the Ozzie track team…….the catastrophic failure of the base bar on day one of the Olympic track program is not a good ad for Bastion at all.

[@tang0oscarmike]

You saw the photo of the bike? It appeared to me to me carbon fibre failure which is Argon’s wheelhouse, rather than Bastion’s.

[@TheRealWai2Fast]

@@tang0oscarmike Argon 18 released a statement confirming the bars that failed was not one of theirs. They stated that they supplied bars, but the team opted not to use the supplied bars.

[@spdaltid]

Looks like the offending item, or similar, at about 7:08. I'm sure Bastion will be gutted as well, and very keen to find the cause. Notwithstanding, a Bastion [Road] bike is still on my wish list!

[@gowenu]

Before commentating on the timing, there are always other mechanical reasons for failure, overtightened screws etc. Let's wait until thorough investigation.

[@patrickparisienne1917]

If I were to buy a “once in a lifetime” boutique bike, it would be a Bastion, no doubt. Shame about their public bar failure, but I’m sure they’ll learn from it.

[@bradallen8643]

I hope they publicly release the findings of their investigation into the cause of the handlebar failure.

[@nickmcalinden5661]

Or a Prova. 🚵🏻‍♂️

[@WowRixter]

Despite what happened at the Olympics, that was still a remarkably interesting video. More like this please

[@sc0608023]

Bastion is probably the single most interesting bicycle company to date ;D

[@splashpit]

Really when all they are doing is what Alan were doing 30 years ago .

[@jpvdw1961]

Bill Holland, Holland Cycles, out of So Cal

[@PInk77W1]

As each of our builds are bespoke to their owner, price is upon application, however most Crossroad customers spend in the vicinity of AUD 25,000

[@neilwheel]

Be careful what you wish for ...

[@involuntarysoul3867]

3d printed titanium is just terrible, there is no reason for it when carbon fiber is so much better

[@chrisvanbuggenum871]

I don't know. Using lugs seems like old ideas with moderns technology. Despite that i still thought some of them looked gorgeous, but i went on the website and was blown away by the cost. I would never pay more than the cost of a Tarmac SL7 which is 18k AUD, which is heaps.

[@nickmcalinden5661]

A tarmac SL7 is a mass produced bike just like the rest. An S-WORKS Tarmac is AU$20,100. If I had the money, and wanted to spent $20K on a bike. I would definitely get a custom made bike over a mass produced bike. A Prova or a Bastion for sure. unfortunately that’s not going to happen…. Great to dream and talk about these things though. 😎🚵🏻‍♂️

[@TheReal_JohnDoeSmith]

Why do Aussies Emphasize short consonants and long vowels? Reminds me of the Cali Valley girl vibe from the 80’s. Starting a sentence with a conjunction too……”So”, we do this and…….. What do the Metallurgic X-rays show on the densities of this powder and final product?

[@global_nomad.]

been following Bastion for. a few years and waiting for the time when i can get one of their bikes....

[@HaydnHamilton]

Designer be looking for new job soon....or a brand new million dolla Xray machine to check for internal flaws that missed the QC eyeballs

[@STIXEY1]

Where were the Q.A. protocols?? - on the post Polishing of the components???......and the answer is??

[@tonychopper5758]

Is this the guy who USED to work for Bastion cycle? Have they accepted it was a bad idea.

[@craiggruber3024]

How not to print ....

[@recyclespinning9839]

So des the Bond to carbon fiber come loose? Start your explanation by why this method is better?

[@richardhaselwood9478]

Really enjoyed that one. Bastion do make some lovely bikes. More importantly, they actually seem to employ some competent engineers, unlike most of the bike industry Also, good public statement about the failure of one of their components on the Aus track team bikes (ie. We need to get the bottom of it)

[@nguyenho9591]

Yall really posted this video at the right time

[@davidpinnington213]

Ah timing - saw a Bastion when i worked in Dubai 2-3 years back after fist becoming aware via Pinterest- works of art and some serious investment - wattshop mentioned elsewhere on here subcontracts out their printing as they did with the previous aerobars (got a set of their carbon version) - lugs/nodes etc - perfectly normal for engineering and construction and for cycles Atherton follow a similar process I think - come the time for my one road/gravel/grail bikes Bastion is on my list

[@eijiroinouye4115]

I have a Litespeed Ultimate Gravel frame. Is it still a nice frame or is it now older technology?

[@RudiDwiHartanto]

and you wonder why pentaxia and anemoi wattshop extension cost so high

[@ajthmmht]

Damn such underrated video :((

[@ancogbernard]

wish they will build bike that fully titanium

[@juansaladzar]

Breathe in that titanium powder brah 👍

[@hotcakes1117]

I know they mentioned size restrictions and the time would be an age but id love to see a full frame built up just from the Ti dust to full frame

[@hectorkidds9840]

Suspect that would be very heavy, pretty sure you get much better properties out of a titanium tube than you can with printed component. Can weld tubes to the lugs though, so it can all be titanium.

[@robvanderwilk7159]

Cool!

[@Princess_minseo]

china carbon better