Cycling for All: Liberty Pattern and Heavy Bikes 3D Print Strong, Lightweight Frames
When they’re ready to ride, cyclists expect their bikes to be strong, safe, and durable. But many traditional bikes on the market aren’t designed to support riders of different shapes and sizes who need frames that can accommodate unique riding styles.
Conventional welded bike frames have weak points that are prone to failure. Inconsistencies in legacy metal casting production can lead to integrity issues caused by inclusions, porosity, or shrinkage.
Industrial control and automation specialist by day and avid cyclist by night, Charlie Murray wanted to weave modern technology into the centuries-old metal casting process to eliminate these concerns. Working alongside foundry professionals, he formed Foundry Casting Systems (FCS) and developed the Pascal Process. This pressurized casting method creates higher-density, less-porous parts; it solidifies sandcasting by pumping inert gas into a mold to ensure a properly filled part every time.
To demonstrate the capabilities of the Pascal Process, Murray decided to use it to build a bike frame—one that wouldn’t require welds. When his prototype was ready, he called on the University of Northern Iowa’s Metal Casting & Foundry 4.0 Centers to put it to the test. That’s where he saw binder jetting, a form of 3D printing, in action for the first time. Because it creates molds from silica sand and furan binder, the technology eliminates costly and time-consuming tooling production to move innovations from concept to execution faster.
One year later, when Murray discovered Liberty Pattern Company, it was like finding a missing puzzle piece. With six ExOne S-Max 3D binder jetting systems in its pattern shop, Liberty Pattern could bring 3D printing and foundry casting together cost-effectively. The team could help Murray’s prototype frame quickly become a production model so he could bring his company, Heavy Bikes, to life.
Its foundry molds and cores enable bike frame walls to be stronger, thinner, and lighter than traditional hollow-tube aluminum frames. Because 3D printing supports low-volume projects, it also makes customization possible for every bike being produced.
Working through several iterations of frame design, Liberty Pattern is helping Heavy Bikes give cyclists exactly what they need: strong, durable, single-piece aluminum frames that are almost like tailored works of 3D art. Now, riders can be confident their bikes will perform at a high level for decades to come.
Want to learn more about the Heavy Bikes story (and uncover the reason behind the company’s name, despite its lightweight design)? Read the full case study.
