In the quest for ever-lighter, stronger, and more bespoke cycling hardware, conventional carbon-layup methods—while proven—can be costly, labor-intensive, and geometrically limited. At Reinforce 3D, we’ve leveraged our Continuous Fiber Injection Process (CFIP) to bring composites into the cycling world, marrying additive manufacturing with automated, targeted fiber reinforcement.
The manufacturing challenge in cycling
- Manual layup dependency: High-end saddles, handlebars, and other components are still hand-built, restricting scalability and driving up costs.
- Design vs. structural needs: Rider’s demand complex ergonomic shapes and integrated mounts, yet those shapes must withstand high loads, fatigue, and impacts.
- Lightweight, on-demand production: Brands seek low-volume, customizable runs without the overhead of tooling and molds.
CFIP integrates continuous carbon fibers directly into 3D-printed cavities, reinforcing only critical load paths and eliminating mold scrap. The result is ultra-light, high-strength, and fully customizable parts manufactured on-demand.
| Feature | Traditional layup | CFIP + 3D printing |
| Labor time | Hours per part | Minutes per part |
| Tooling costs | High (molds, jigs) | None (digital workflow) |
| Fiber placement | Manual, imprecise | Automated, precisely targeted |
| Geometry freedom | Mold-limited | Full 3D complexity |
| Customization | Costly per batch | Native to digital design |
Product portfolio
| Image | Component | 3D print tech & material | Reinforcement | Weight | Benefits |
 | Bottle Cage | FFF in PET-G | CFIP carbon fibers | 38 g | Impact-proof; 25% lighter than aluminum |
 | Saddle | MJF in PA12 | CFIP + titanium rails | 162 g | Ergonomic lattice; no cracking |
 | Handlebar | MJF in PA12 | CFIP + pultruded tubes | 195 g | Aerodynamic profile; high stiffness |
 | GPS Mount | SLA in transparent resin | CFIP carbon fibers | 25 g | Vibration-resistant; device-agnostic |
Technical & business impact
- Weight savings: Up to 70% lighter than conventional composites.
- Rapid turnaround: From CAD to finished part in 1–2 working days.
- Low CAPEX: No molds—perfect for prototyping, custom runs, or on-demand stock.
- Scalable workflow: Digital process scales linearly with printer capacity, not mold inventory.
By combining additive manufacturing with CFIP, Reinforce 3D delivers cycling components that push performance envelopes: lightweight, robust, and fully customized—all without the constraints of traditional molds or manual layups.
Cycling brands and product developers can now rapidly prototype and scale production of ultra-high-performance parts. Ready to revolutionize your lineup?
Contact us for a technical consultation or sample components.
| 🌐 www.reinforce3d.com | 📧 info@reinforce3d.com |
