At the recent MADE Show, a standout creation emerged from TBD Bikes, the company spearheaded by Dylan Banera, known for its innovative 3D printed bicycle designs. Having previously unveiled a proof-of-concept bike at Sea Otter earlier in the year, Dylan returned with a fully functional dirt jump bike prototype fabricated primarily using aluminum through advanced 3D printing techniques.
Dylan successfully brought this bike to life from concept to prototype in a remarkably short time by leveraging 3D printing. The new frame stands in contrast to his earlier model, which was non-rideable. This latest iteration emphasizes durability and rideability, achieving this through nearly complete aluminum construction rather than the previous carbon and Nylon materials.
Key features of the new design include striking components made with AI-assisted design software, particularly in the head tube and bottom bracket areas. Dylan explored this AI design tool to enhance the bike’s physicality, resulting in a unique bottom bracket assembly reminiscent of a human pelvis, equipped with a shelf that theoretically could accommodate a belt-drive setup. However, the lack of a split in the frame suggests this feature may not be practically utilized.
Additionally, Dylan incorporated Triply Periodic Minimal Surfaces (TPMS) into the tubing design—an elaborate choice given its unnecessary complexity for a dirt jump bike. Despite this, the aesthetically pleasing structure showcases the innovative capabilities of 3D printing.
Beyond this dirt jump bike, Dylan is also developing another frame that will feature fully 3D machined elements bonded to carbon tubes, further pushing the boundaries of bicycle engineering and design.
For more information about Dylan Banera’s projects, visit TBD Bikes.