Redefining Bicycle Engineering with 3DFiT
CarbonForm 3DFiT
redefines composite
bike frame manufacturing.
Lighter, stronger,
and mold-free.
3D Fiber Tethering (3DFiT) enables continuous carbon fiber steering along stress-optimized paths, creating seamless composite bike frames.
High-performance frames that are lightweight, structurally efficient, and tailored for competitive cycling and urban mobility alike.
Traditional bike frames are made from welded aluminum, carbon fiber layups, or steel tubing - each with its own tradeoffs:
Aluminum and steel frames are strong but heavy and prone to fatigue
Carbon fiber frames offer weight savings but require complex manual layups, molds, and long cure cycles
Tube-and-joint designs limit geometry flexibility and create stress concentrations at joints
Custom geometries are expensive and slow to produce, limiting innovation in ride performance and personalization
Our 3D Fiber Tethering (3DFiT) solution offers-
Continuous carbon fibers are steered along primary load paths—eliminating joints and maximizing fatigue life
No molds or layups: Fully 3D-printed truss and monocoque designs made directly from thermoset composites
Geometry freedom to integrate truss structures, lattice damping zones, and aerodynamic profiles
Fast customization: Print-to-fit designs tailored to body geometry, riding style, or specific terrain
For the first time, a full bicycle frame was fabricated from a single continuous carbon fiber tow, without the use of molds, joints, or traditional layups—made possible entirely by 3DFiT. This monolithic frame showcases not only unprecedented design freedom, but also maximizes strength-to-weight efficiency by aligning every fiber along structural load paths.Unlike conventional composite bikes that rely on segment bonding or multi-part layups, the 3DFiT frame is fabricated as one continuous piece, eliminating joints and enabling superior structural integrity. It’s not just a bike; it’s proof that complex, performance-critical consumer products can now be manufactured with true fiber continuity and digital precision
Up to 50% lighter than aluminum frames, with superior strength-to-weight ratio
Joint-free construction eliminates crack-prone welds and improves vibration damping
Tunable stiffness by adjusting fiber paths and architecture for road, gravel, or mountain applications
Rapid prototyping to production without tooling—ideal for startups, custom builders, and performance