Additively manufactured steel bike frames by Urwahn, Trumpf, and H+E
March 20, 2025
German companies Urwahn Engineering GmbH, Magdeburg; Trumpf, based in Ditzingen; and H+E Produktentwicklung GmbH, Moritzburg, have partnered to develop SOFTRIDE steel bike frames. These frames –created through a combination of Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing with engineering-based design – are reported to offer improvements of up to 30% in weight, stiffness, and cost.
The new SOFTRIDE steel frame has been specifically designed for the Additive Manufacturing process, offering the aesthetic of a monocoque carbon frame and the light weight of aluminium. Trumpf provided the machinery and material parameters, while H+E – an experienced partner – established the entire process for serial production and contributed feedback to optimise the frame design. Urwahn consolidated all insights and integrated them in line with its development requirements.
As the Additive Manufacturing process reduces post-processing steps such as welding or extensive mechanical machining, it is able to significantly enhance manufacturing efficiency and improve Urwahn’s production process.
Using PBF-LB Additive Manufacturing gave the project’s engineers the design freedom to create structures with internal cavities impossible to replicate with traditional manufacturing methods. Through topology optimisation, load paths have been enhanced, leading to increased stability while reducing component weight.
PBF-LB also allowed Urwahn precise control over layer construction, allowing the final product to have fine-tuned mechanical properties. The use of high-alloy steels and specially developed alloying additives is said to have resulted in a good combination of strength and elasticity.
The collaboration between the three companies progressed from the first sketch to serial production in less than eight months – noted by Urwahn as an unprecedented pace within the industry. The frame is manufactured in larger quantities using Trumpf’s TruPrint 2000 PBF-LB Additive Manufacturing machine at H+E Produktentwicklung in Moritzburg.
The companies hope that this venture can demonstrate how Additive Manufacturing and strategic partnerships can support the development of the bike industry.
