Bicycle Dropouts
Titanium 3D-printed bicycle dropouts designed for Davidson bicycles.
Why I made this
Ashmun Group LCC. was tasked by Davidson bicycles to design and develop new dropouts for their custom bikes.
The resulting 3D-printed titanium drop outs created a more seamless design while reducing manufacturing and assembly times, components, and cost.
Design Brief
The project began with client meetings to establish the project goals and design requirements. Sketches were made to prototype design options and clarify functional requirements.
In addition, meetings were held with titanium 3D printing companies and metal 3D printing experts to determine requirements or restrictions for the design and evaluate the prototypes.
Prototypes
Multiple iterations of plastic 3D printed prototypes were generated to check fit and clearances and improve the design.
Next, an initial set of dropouts were printed in titanium with various finishing treatments to be tested on a prototype assembly for fit, assembly, and strength. Following additional client meetings, the designs were refined, including significant weight reduction, to create the final dropouts.
Final Design
The final dropout design combined the drive and drive side dropouts, brake caliper mounts, and derailleur hangers into two cohesive parts that blend smoothly with the frame tubes. The designs minimize assembly and manufacturing time, thereby reducing cost, and improve the aesthetics to create a seamless frame design. The final dropouts have been confirmed through another round of 3D printed titanium parts, tested on a prototype bicycle, and shortly will begin being used on all full bicycle assemblies.
The new designs are being used on custom bikes today!