3D Printed BicyclesConsumer ProductsSports Equipment

Italy to ride new 3D printed Scalmalloy Bolide F HR bikes at Olympic Games

Two new incarnations of the Hour Record-winning bikes from Pinarello are ready for Paris 2024 competition

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The men’s endurance squad, the reigning Olympic champions, have received 3D printed scalmalloy versions of this revolutionary track bike – the Bolide F HR 3D – while the women’s endurance athletes will compete on a custom carbon model – the Bolide HR C. These are two new incarnations of the Hour Record-winning Bolide F HR by Pinarello, which it hopes will propel the men’s and women’s Italian track cycling teams to victory in the team pursuit at the Paris 2024 Olympic Games.

The Bolide F HR 3D was initially developed for Filippo Ganna’s successful Hour Record attempt on Saturday 8th October 2022 where he set a new, yet unsurpassed benchmark of 56.792km in Grenchen, Switzerland.

A groundbreaking champion

The Bolide F HR 3D is a pioneering high-performance 3D printed bike, marking a significant milestone in innovation. Retaining its hallmark features, these latest iterations are a testament to its continued excellence. Key features include the incorporation of AirStream technology, a collaborative effort with the University of Adelaide and aerodynamics R&D partner NablaFlow. Inspired by the tubercules found on the flippers of humpback whales, this technology integrates a unique pattern of AeroNodes onto the seat tube and seat post. Their purpose is to mitigate the complex vortexes generated by riders’ leg movements, thereby enhancing airflow.

Italy's Men and Women teams to ride new 3D printed Scalmalloy Bolide F HR bikes from Pinarello at Paris 2024 Olympic Games
The first BOLIDE F HR 3D Replica has been specifically designed for Filippo Ganna’s hour record attempt. The concept behind this unique frame is to blend strength and stiffness with aero gains, relying on a production method that would allow for millimeter-perfect sizing.
The evolution of the fastest bike on the earth is represented by two additional framesets: one made of titanium and the other in carbon fiber.

Additionally, the inclusion of AirFoil sections on the bottom bracket and wheel hubs, characterized by longer and slimmer profiles, serves to diminish frontal area, capitalizing on advancements allowed by the UCI’s relaxation of the 3:1 rule. Extensive research has revealed that aspect ratios of 6:1 and even 8:1 outperform the original benchmark. Furthermore, the decision to employ narrow forks and seat stays underscores a departure from prevailing trends favoring wider structures, driven by a commitment to minimize overall drag and optimize frame weight for superior performance.

This approach was informed by meticulous Computational Fluid Dynamics (CFD) testing, in collaboration with NablaFlow utilizing their AeroCloud software, hosted on AWS. Through iterative simulations, the most efficient handlebar geometry was achieved, further enhancing the bike’s aerodynamic prowess and consolidating its position at the forefront of innovation in cycling technology.

Italy's Men and Women teams to ride new 3D printed Scalmalloy Bolide F HR bikes from Pinarello at Paris 2024 Olympic Games
Custom 3D printed to fit, and with a price tag of € 28.750 (VAT Excluded), the BOLIDE F HR frame achieves the same performance in terms of speed compared to the 3D Replica model, reaching a production standard that makes this model available to the public.

Cutting-edge 3D printing

Pinarello has led the way in 3D bicycle printing technology since 2015 and spent countless hours developing the Bolide F HR 3D’s innovative design. Each frame incorporates just five parts; with the front triangle comprising three pieces in addition to seat and chain stays.

Scalmalloy was selected for the men’s model as its properties allow it to excel under the increased forces and speed the male athletes produce, while the lighter carbon Bolide F HR C model will allow the female athletes to get up to speed in the fastest possible time.

Both new models share the same geometries and dimensions as the original Bolide F HR 3D and are available in three standard frame sizes. Each one has been checked and approved by the UCI and are available for the general public and other teams to purchase.

The newly developed handlebar and extensions allow for precise positioning and optimal aero advantages.

Research
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Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based VoxelMatters. Today the company publishes the leading news and insights websites VoxelMatters.com and Replicatore.it, as well as VoxelMatters Directory, the largest global directory of companies in the additive manufacturing industry.

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