EADS unveils bicycle that is 'grown' from fine powder

Made from nylon, the Airbike technology demonstrator was assembled using Additive Layer Manufacturing (ALM) at a centre located next to Airbus’s site at Filton.

The process allows complete sections to be built as one piece; the wheels, bearings and axle being incorporated within the ‘growing’ process and built at the same time.

Similar in concept to 3D printing, the bike design is perfected using computer-aided design and then constructed using a laser-sintering process that adds successive, thin layers of the chosen structural material until a solid, fully formed bike emerges.

EADS said that it has developed the technology to the extent that it can manipulate metals, nylon and carbon-reinforced plastics at a molecular level, which allows it to be applied to high-stress, safety-critical aviation uses.

Compared with a traditional, machined part, those produced by ALM are said to be up to 65 per cent lighter but still as strong. The technology is likely to be employed eventually in industrial applications such as aerospace, the motor industry and engineering.