TREK Bicycles prototest using functional 3D Printed parts

Trek Bicycles uses Objet 3D printers and the ABS-like materials to rapidly prototype functional bike parts that can be tested on real bikes - in the field - just 2 hours after on-screen design.

The 3D printing process saves weeks from the conventional CNC milling process, and allows them to perfect their design parts before full production:

• TREK were considering buying an SLA (Stereolithography) machine, an established rapid prototyping technology
• The company knew that SLA could make great parts that customers would like, but wanted to explore all options
• They were attracted by the ability of the Objet Connex 3D Printer to use multiple "digital" materials in the design process
• Looking closer at SLA they found that there was an overhead in post-processing - 4 people to finalize parts - which they viewed as a 'hidden cost'
• Objet Connex offered them a relatively simpler process, with less post-processing overhead
• For TREK, traditional CNC machined parts came with a typical 28 day backlog - that's a big impact if the part is wrong and another machine-run is required
• With Objet Connex the turnaround is 1 day - allowing for multiple iterations in the design process
• It turned out that the ABS-like 3D printed parts are strong enough even for testing brackets under stress
• TREK engineers were amazed at the first parts that came out of the Connex - a real part 'in your hand'