Aero 3D Printed Titanium Bike Debuts at MADE: No. 22's Reactor Pushes Boundaries

When it comes to modern bicycles, off-the-shelf models are often the speedier choice compared to custom builds. Factory production allows for greater optimisation, resulting in lighter frames, though this isn't always the case. Perhaps more crucially, aerodynamic considerations tend to favour production bikes.

Large companies have access to advanced computational fluid dynamics (CFD) simulations and wind tunnels during the design process, enabling them to achieve intricate tube shapes that are difficult to replicate. This holds true even for custom carbon frames. If a metal bike is your preference, it's rarely considered a serious contender for aerodynamic performance. However, the rise of 3D printing is starting to challenge this notion.

No. 22, known for their handcrafted titanium bikes with a contemporary aesthetic, has taken a bold step forward. They recently unveiled the world's first fully 3D printed titanium bike, the Reactor. Building upon the successes of others experimenting with small 3D printed components, No. 22 is creating previously impossible geometries. The Reactor, however, goes beyond mere novelty; it redefines what a custom metal bike can achieve, delivering aerodynamic performance alongside its titanium character.

The No. 22 team began the development process with CFD analysis, aiming to combine the unique properties of titanium with a deep understanding of airflow. As Bryce Gracey, No. 22 co-founder, explains, the Reactor isn't merely a showcase for 3D printed titanium. It maintains the feeling of a titanium bike while utilising the technology to create otherwise impossible aero tube shapes. The entire frame is printed as a single piece, enhancing its aerodynamic qualities.

The 3D printing extends beyond the frame. The build incorporates components from various companies, utilising the technology where possible. A notable example is the brand's own 3D printed, internally routed stem. While the handlebar appears to be 3D printed, it's actually an Enve Aero IN-Route Handlebar with meticulous attention to detail and paintwork.

3D printing also features on the Scope Artech 4 wheelset, which we recently reviewed. The construction utilises carbon with biomimicry inspired by fish scales for optimal aerodynamics. The hub, however, is truly unique. Scope employs 3D printed Scalmalloy, an additive manufacturing substitute for 7000 series aluminium alloys, to create intricate shapes. These lightweight, bone-like structures weigh in at a mere 220 grams for both hubs while maintaining the necessary stiffness.

The groupset is provided by SRAM, featuring the recently released SRAM RED 2x road system. Although a UDH is not required for the road version of the groupset, No. 22 opted to incorporate it into the chainstay design. The bike also boasts a CeramicSpeed pulley, although instead of a 3D printed version, it employs the CeramicSpeed OSPW Aero ALPHA system. This was likely a challenging decision, as both options offered unique advantages.

Rounding out the groupset is a titanium crank. No. 22 typically utilises Cane Creek eeWings Titanium Cranks, but this time, they have chosen a 5DEV Road crank. First seen at Sea Otter, the crank is CNC machined and laser welded in California. It features a unique finish and lacks the 5DEV branding.

The final noteworthy component is the saddle. Berk saddles, crafted by a former road racer, are known for their exceptional comfort, light weight, and aesthetic appeal. They are also handmade in Slovenia. This build features the recently released Lupina Monocoque Open saddle, upholstered with black leather.

This is an exceptionally high-end build, even without considering the cost of 3D printing a complete bike frame from Grade 5 titanium powder. At present, the Reactor is a prototype. Gracey confirms that the next steps involve further aerodynamic testing and refinement, with hopes of bringing it to market in the third or fourth quarter of 2025.

For more information and, eventually, purchasing details, visit the No. 22 website.