Arevo and Superstrata present 3D printed unibody carbon fiber bikes

Arevo and Superstrata have just unveiled new 3D printed unibody bicycles, unique in both the design and properties. Last year, Arevo, a California-based additive manufacturing startup, built the first 3D printed carbon fiber unibody bike frame. The e-bikes were called Emery One, but only a few of them were sold. However, now, Emery One is seen more as a prototype: an early version of the outstanding Superstrata models. Let’s find out what is special about Superstrata 3D printed bikes.

Typically, the 3D printed frames consist of several elements that are glued and welded together. The biggest disadvantage of that conventional manufacturing technique is that such frames can quite easily fall apart under pressure. Superstrata, which is a brand under Arevo, might not be the pioneer of 3D printing the e-bike frames, but they are the first ones to manufacture the unibody ones, using continuous carbon fiber technology.

Superstrata 3D printed bike in white color. (All image credits: Superstrata)

The typical technology to achieve continuous fiber reinforcement relies on the extrusion process (usually with two printheads: one prints the thermoplastic and the other the carbon fiber). AREVO’s proprietary process based on Directed Energy Deposition technology is quite different. A laser is used to heat the filament and carbon fiber at the same time as a roller compresses the two together.