DMLS 3D Printed Titanium Alloy Bicycle Hand Brake Prototype

DMLS 3D Printed Titanium Alloy Bicycle Hand Brake Prototype

Process 3D Print
Material Metal
Quantity 1 pcs
Price Range $100-1,000
Lead Time 3 workdays


About Project

This innovative bicycle hand brake prototype is pushing the boundaries of cycling technology. Crafted using DMLS (Direct Metal Laser Sintering), a type of 3D printing, the brake lever boasts an intricate lattice structure on the upper portion. This design choice is likely twofold:

Strength: The lattice structure provides exceptional strength, ensuring the brake lever can withstand the demands of cycling.
Weight Reduction: By utilizing a lattice instead of solid material, the designers have significantly reduced the weight of the brake lever without compromising its integrity. This translates to a lighter overall bike frame, enhancing performance.

The handle section of the brake lever is purposefully designed for optimal rider comfort and control. A solid construction ensures a secure grip, while the textured surface prevents slippage even in wet conditions.

This 3D printed titanium alloy brake lever prototype showcases the immense potential of additive manufacturing in the cycling industry. By combining lightweight materials with innovative design, manufacturers can create high-performance components that elevate the rider's experience.

Ready to push the limits of design and functionality with 3D printing? FacFox is your one-stop shop for exceptional 3D printing services. We offer cutting-edge DMLS technology, a wide range of materials like titanium alloy, and a team of experts to bring your ideas to life. Contact FacFox today and see how 3D printing can revolutionize your next cycling project.


  • Step 1: Designing. Initially, a detailed 3D model of the bicycle hand brake was created using computer-aided design (CAD) software. The model included an intricate lattice structure on the upper part of the brake lever and a solid handle with a textured surface.
  • Step 2: Slicing. The CAD model was then sliced into thin horizontal layers, converting it into a file format suitable for the DMLS printer.
  • Step 3: Printing Preparation. A bed of titanium alloy powder was prepared in the DMLS machine, and the printing parameters were set according to the requirements of the prototype.
  • Step 4: Layering. The DMLS printer spread a thin layer of titanium powder onto the build platform.
  • Step 5: Sintering. A high-powered laser selectively sintered the first layer of powder, fusing the titanium particles together to form a solid layer.
  • Step 6: Adding Layers. The build platform was lowered, and a new layer of powder was applied over the sintered layer. This process was repeated, with each layer being sintered on top of the previous one, building the brake lever layer by layer.
  • Step 7: Cooling. After the final layer was sintered, the build chamber was allowed to cool down gradually to ensure the structural integrity of the brake lever.
  • Step 8: Removal. The excess powder was removed, revealing the completed brake lever. The intricate lattice structure and the solid handle with the textured surface were clearly defined.
  • Step 9: Post-Processing. The brake lever underwent various post-processing steps, including heat treatment to relieve residual stresses and improve mechanical properties.
  • Step 10: Finishing. Finally, the brake lever was subjected to surface finishing techniques to achieve the desired surface texture and to enhance the grip of the handle.