HBD brings metal 3D printing to titanium bicycle production

Hi-Light Titanium Bicycles, a manufacturer specializing in custom-built titanium frames, is now adopting metal additive manufacturing to address these challenges. The company has partnered with HBD Additive Manufacturing to integrate industrial-grade 3D printing into its production workflow.

Titanium has long been a preferred material in high-end bicycle manufacturing due to its strength-to-weight ratio and corrosion resistance. But as demand grows for lighter, more aerodynamic frames and shorter lead times, conventional methods such as welding and machining are hitting performance and cost limits.

Since 2024, HBD has increased its development and investment in 3D printing technologies. The addition of titanium 3D printing offers advantages such as optimized design, rapid prototyping, small-batch production, customization, and lightweight construction. According to the company, these capabilities are becoming a significant trend across the broader manufacturing sector.

Currently, Hi-Light uses precision casting for mass production and applies 3D printing primarily to small-batch customized products. This hybrid model addresses the growing demand for weight reduction and structural integration in cycling components, while also avoiding the high cost and environmental impact typically associated with low-volume manufacturing. HBD states that this approach shortens delivery timelines and enhances overall production efficiency.

The collaboration centers on HBD’s metal 3D printing technology, which supports complex geometries and function-driven designs. Using topology optimization and simulation tools, Hi-Light is creating lighter, stiffer, and more integrated frame structures that would be impractical or impossible to achieve with traditional manufacturing.

One key benefit is the ability to consolidate multi-part welded assemblies into single printed components, reducing weak points and improving reliability. The design flexibility also supports aerodynamic enhancements such as streamlined frame profiles and concealed cable routing, which are increasingly critical for performance-focused cycling.

Production speed is another focus. HBD’s 400-series printer uses multiple lasers to fabricate different parts in a single build, enabling parallel production and reducing lead times by more than 50%, according to the company. This shift allows Hi-Light to serve over 100 international customers with tailored designs without compromising delivery timelines.

Looking ahead, HBD plans to scale its titanium 3D printing capabilities to produce more than 50,000 bicycle frames and parts annually. These components will be applied across a range of bicycle models, with the goal of delivering higher strength, lighter weight, and improved durability for customers worldwide.

HBD reports that its collaboration with Hi-Light reflects a broader shift toward digital, flexible manufacturing in the cycling industry. The company says it plans to expand its industry-specific application development and continue working with manufacturers in other sectors to scale adoption of metal additive processes.