Single-Piece Bike Frames Cast in Aluminum with 3D Printed Molds 

Heavy Bikes produces customized, single-piece cast bike frames with binder jet sand 3D printing technology 

Digital production technologies like binder jet 3D printing eliminate the cost and long lead times of traditional tooling, making casting a viable option for a wider range of products, even at low volumes.

Heavy Bikes are ISO 4210:2015 compliant custom one-of-one cast aluminum gravel bikes for any size of rider. The build process starts with a custom bike fit which drives the 3D printed sand mold design. Molds are filled with molten A356 aluminum with Foundry Casting Systems’ Pressurized Solidification process to ensure a properly filled mold and superior mechanical properties. 

“3D printing enables people to explore casting. They might have been shunned away because of the tooling costs or because of the iteration costs in the past. Binder jetting opens that door.”

Charlie Murray, Co-Founder of Foundry Casting Systems & Heavy Bikes

Download the case study to learn abouthow the S-Max binder jetting platform is helping innovate new products and get them to market faster.