No. 22 to launch aero-optimized road bicycle with 3D printed titanium frame

Founded in 2012 and based out of Johnston, New York, No. 22 Bicycle Company specializes in the design and production of titanium bikes. The company, which prides itself on fabricating bike components in house or sourcing them from US-based suppliers, relies on a combination of advanced manufacturing processes, such as EDM wire cutting and laser sintering 3D printing, and more traditional craftsmanship to deliver two-wheelers that are optimized for performance and to the rider. Now, No. 22 has unveiled the first glimpses of what it calls the “world’s first fully aero titanium road bicycle”. The bike, called the Reactor Aero, integrates a number of 3D printed titanium components and will officially launch in 2025. For now, what we know is based on the Reactor Aero prototype, which is being showcased at the MADE bike show in Portland, Oregon until August 25th.

The Reactor Aero is the first aero-optimized titanium bicycle of its kind, meaning that it has undergone extensive aerodynamic testing—including CFD simulations—and is intended for racing. No. 22 says the bike has already undergone testing that confirms 30-40% drag reduction compared to its Aurora bike model, and will be put through additional wind tunnel testing and validation before it officially launches.

The bike itself integrates a number of optimized 3D printed components, including the down tube, bottom bracket intersection and chain stays. The current prototype (pictured) also features a fully 3D printed frame made from Grade 5 titanium. The prototype frame was printed in a single piece (except for the seat tube, which is a carbon-based integrated seat post co-developed with July Bicycles), however the production version will be printed in sections that will be machined and welded in house to enable No. 22 to exact the tightest controls over tolerances, finishes and quality.

“3D printed titanium has phenomenal structural properties,” explained Bryce Gracey, Co-Founder of No. 22. “The ability to print internal support structures anywhere in the frame gives us a level of control over the ride quality that has not been possible before. We are able to add stiffness in high load areas like the bottom bracket, dropouts and head tube for very little weight, while playing with structure in fine detail throughout the frame to ensure it delivers the ride quality we need.”

The Reactor Aero has also been optimized in ways other than aerodynamics: No. 22 says it has improved the bike’s drivetrain stiffness for superior power transfer. This was achieved through the redesign of the aforementioned 3D printed down tube, bottom bracket intersection and chain stays, as well as new tubing profiles and intersections. For those bike enthusiasts in Portland, you can check out the current version of the 3D printed bike at Zidell Yards until August 25th, 2024. No. 22 hasn’t said anything about the cost of the upcoming road bike, though its previous models range from $4,000 to $7,000, which gives an indication of the price point.