Kevin Frias’ ambitious attempt to 3D print his dream Canyon Aeroad bike in just four days ended in disaster—but Canyon Bicycles rewarded his effort with a real bike instead.
Kevin Frias, a Minneapolis native, set out to create a high-performance Canyon Aeroad CF SLX 8 Di2 bike entirely from 3D-printed parts in time for his birthday on March 31. Despite the challenges he faced along the way, the project gained widespread attention and ultimately caught the eye of the brand itself.
“There’s so much more engineering that goes into bikes than people think. I think bikes have been around for so long we take them for granted,” Frias explained after the project concluded.
The Canyon Aeroad CF SLX 8 Di2 is a premium road bike, retailing for more than $6,000. It’s a product of years of research, development, and engineering. Nonetheless, Frias, an industrial engineering graduate and former manufacturer, believed he could replicate it through 3D printing. He had recently purchased a Bambu Lab A1 3D printer and decided to take on the challenge of printing his dream bike in just four days.
“Technology of 3D printing is insane. There are so many models now. You don’t need to know how to design. You can just go download something, buy the filament, and then four hours later, you have this cool, super complex thing,” he said, speaking to Cycling Weekly.
With a background in engineering and content creation, Frias was no stranger to ambitious projects. For the past 18 months, he’s focused on cycling content, traveling the world to experience different riding cultures. But when he realized he didn’t have a road bike back home, he decided to create one.
Determined to have it ready before his birthday, Frias began designing the bike frame by pulling specifications from Canyon’s website. He knew it was an ambitious and likely impractical project, but that didn’t stop him from diving in.
“I looked it up and no one had ever made a bike. Let me try. I don’t know how hard it’s going to be,” he recalled. The project, dubbed “Project #birthdaybike,” began with just a few days to spare.
Frias quickly began learning 3D modeling, focusing on building the handlebar before moving on to other parts. Over the course of the next few days, he printed the bike frame in segments using 6 kilograms of PLA and TPU filaments. He chose these materials due to the high cost of carbon fiber filaments.
However, the process wasn’t easy. Numerous setbacks occurred, including a printing mishap that ruined an entire spool of filament and a miscalculation with the fork’s width. Still, Frias pressed on, gaining a deeper appreciation for the complexity of bike design.
“There is so much more engineering that goes into bikes than people think. The amount of work or design that goes into improving something .0001% is insane,” he said.
The project also highlighted the way bikes can unite people. As Frias’ Instagram videos gained millions of views, strangers reached out to offer support. Five volunteers even lent their own 3D printers, contributing more than 250 cumulative hours of print time to the project.
Despite the community help, 3D printing a bike at home is anything but practical. The fragile, small parts needed to fit together like a jigsaw puzzle, and the weight of the printed material was far heavier than that of a real bike.
“The weight is exponentially heavier than the real one. One wheel from the 3D printed bike weighs more than the real complete bike,” Frias noted.
After a long day of assembly, which included sanding, drilling, and gluing, the bike was finally pieced together. Yet, it was far from functional. Six cracks appeared in the wheels, five in the frame, and parts like the handlebars and wheels couldn’t support any weight. Still, Frias celebrated the completion of the project.
“I made this!” he exclaimed. “Even though this bike was broken everywhere, I’m glad I finished putting it together.”
Although the bike didn’t work as planned, Frias’ efforts impressed Canyon Bicycles. The company, recognizing his enthusiasm and determination, decided to send him the real Canyon Aeroad CF SLX 8 Di2 as a reward.
“Honestly, Kevin’s inspired us all with his love for cycling, his design prowess, his initiative, and his sheer joy in taking on a really tough project,” said Devin Riley, Canyon’s Vice President of Marketing and Sales. “That his dream bike is a Canyon Aeroad puts a smile on our face too.”
While Canyon acknowledged that 3D printing technology isn’t yet advanced enough to produce a fully functional bike, they recognized its potential as a design tool. “Passionate people like Kevin will no doubt be the ones showing us the way,” Riley added.
For Frias, the journey was far from a failure—it was a testament to his creativity, perseverance, and love for cycling. Though his 3D printed bike may not have rolled, his spirit of innovation and enthusiasm for the sport were clear, inspiring both his followers and the brand he admires.
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