THOK and Materialise have introduced 3D printing in the development of e-bikes.
A fully functional prototype of a full-suspension e-MTB made of aluminum was successfully created using selective laser melting (SLM).
The collaboration between THOK and Materialise opens new possibilities for the entire e-bike industry and paves the way for future innovations.
THOK Revolutionizes the E-Bike Industry with 3D Printing Technology.
THOK's prototype of a full-suspension e-MTB made of aluminum, created through 3D printing in collaboration with Materialise; Image: THOK
Italian company THOK has always been synonymous with study, research, and innovation. Now, it is also a pioneer in the use of new technologies for the development of e-MTBs. In collaboration with the company "Materialise," THOK is the world's first e-bike brand to experiment with 3D printing in metal (Selective Laser Melting - SLM) to create a fully functional prototype of a full-suspension e-MTB made of aluminum.
The prototype, temporarily named "THOK Project 4" (P4), is the precursor to THOK's first "light e-MTB" in carbon fiber, set to be released in 2024. It will feature a Bosch SX motor and battery modularity (400 / 545 / 725 Wh + range extender).
Currently, the development is underway, and certain technical decisions are still being evaluated, such as the integrated or semi-integrated battery, component configuration, and geometric choices. However, the frame created through 3D prototyping is already undergoing testing on the technical trails of Finale Ligure and THOK E-Bikes headquarters in Alba.
The advantages of rapid prototyping with 3D printing lie in producing functional models that allow for testing of geometry, suspension, and component integration. SLM enables the creation of lightweight parts that simulate the weights of the final carbon fiber bicycle.
To facilitate this significant transition, THOK sought a partner of excellence, which led to the selection of Materialise, a Belgian company with offices in 20 countries worldwide.
Materialise specializes in 3D printing for the aerospace, automotive, and medical sectors. The chosen technology, Selective Laser Melting (SLM), utilizes lasers to melt metal powder. For the Thok P4 prototype, an aluminum-silicon alloy (AlSi10Mg) was chosen due to its strength, thermal properties, weight, and post-machining flexibility.
The collaboration between THOK and Materialise presented both companies with unprecedented challenges, particularly concerning the interaction of metal printed parts and the machining of kinematic mechanism housings and component interfaces.
Simone Cannella, Business Development Manager at Materialise, explains, "The project with THOK allowed us to extend our experience into the bicycle sector and take metal 3D printing to a new level. This collaboration provided us with the opportunity to refine our metal additive manufacturing capabilities to meet the specific requirements of the Italian company."
While the future of 3D printing remains to be seen, the experimentation conducted by THOK and Materialise represents a pioneering chapter in this story, bringing innovation to the global e-bike industry.
