Leading titanium bike manufacturer looks to produce 50,000 metal AM parts annually
August 29, 2024
Following the introduction of China’s first titanium alloy bike under the Hi-Light brand in 1992, Hanglun Technology is now reported to be the world’s largest manufacturer of titanium alloy bikes. With an annual production capacity of nearly 20,000 titanium alloy frames, Hanglun supplies a number of leading global brands.
With a strong presence in high-end bicycle markets across North America, Europe, and Southeast Asia, Hanglun Technology also dominates the Chinese sports cycling market. With custom-engineered titanium alloy bike frames, handlebars, and other key components, the company reportedly captures 80% of the Chinese domestic market.
In 2023, Hanglun Technology made a strategic investment in the FS350M 4-laser metal Additive Manufacturing machine from Farsoon Technologies, based in Changsha, China. The company stated that it aims to additively manufacture over 50,000 titanium bicycle components annually, for use in both high-volume production and custom models.
“3D printing is a game-changer in our industry and is leading the way in innovation. It pairs perfectly with traditional precision casting,” stated Yanpeng Yang, Vice General Manager, Hanglun Technology. “Right now, we use precision casting for big production runs and 3D printing for those smaller, custom projects. This mix lets us create lighter, more complex, and highly customised bicycle parts. Plus, it helps us cut down on costs and environmental impact for small-batch production, speeds up delivery times, and makes the whole process smoother and more efficient.”
In the product design and development phase, Additive Manufacturing enables rapid iterations of titanium alloy bicycle components to be produced, significantly speeding up the design process. AM technology also leads to higher quality, enhanced performance, and more reliable components, explains Hanglun.
For example, the technology allows for the seamless integration of complex structures into a single piece. To further minimise air resistance, the company has also integrated cables and components for braking and shifting directly into the AM frame, enhancing overall efficiency.
The AM process also has significant advantages over traditional welding methods, which can cause issues such as deformation, fatigue damage from residual stresses, and problems with size accuracy and poor connections. Welding can also lead to slightly heavier titanium alloy frames due to the added weight of welding materials.
Performance tests on titanium bicycle components produced with the FS350M-4 machine have also shown improved mechanical properties, with a tensile strength of 1035 MPa, a yield strength of 998 MPa, and an elongation at break of 13.5%. These enhancements significantly extend the lifespan of the components, underscoring the advanced capabilities of AM technology in producing high-performance parts.
By combining topology optimisation with Additive Manufacturing, Hanglun can achieve a reduction in full-frame weight to just 1.4 kg. For cyclists, this means increased speed and reduced turbulence during long-distance rides, offering smoother, faster, and more efficient cycling.
According to Farsoon, by embracing Additive Manufacturing, Hanglun not only elevates the performance, efficiency, and design of its bicycles, but also strengthens the legacy of the Hi-Light brand with its continuous technological advancements.
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