Application of the week: Custom aerobar mount for road bikes

Welcome back to our application spotlight series, where we explore how 3D printing transforms real-world challenges into smart, cost-effective solutions. This week, we’re shifting gears from industrial lines to the world of high-performance cycling, with an innovative custom bike mount made possible by UltiMaker S8.

Precision performance on two wheels

At Wielerhuis Marel, a specialized bike workshop in the Netherlands, owner and head mechanic Pim van der Marel faced a unique problem. A customer wanted to mount a set of aerobars onto a road bike, but the bike’s handlebar design didn’t support standard mounting hardware.

Traditionally, this would be a dead end. But with the help of additive manufacturing, Pim created a completely customized aerobar mount and bridge that fit the bike perfectly - offering a stable, durable solution with low cost and high functionality.

Why 3D printing made sense

“This problem couldn’t be fixed before,” Pim says. “There was no existing solution that fit.” So instead of compromising the bike setup or ditching the aerobars altogether, he turned to 3D printing - a smart choice for one-off parts that demand precise dimensions and strength.

Printed on UltiMaker S8, Pim could leverage the open material system and dual extrusion capabilities. Using TPU and Nylon CF Slide, the custom part was both strong and lightweight - ideal for cycling applications. PLA was used to quickly prototype and test the shape before moving to the final print.

From idea to ride in a few steps

The process followed a lean and efficient workflow:

1. Brainstorming the concept
2. Measuring the bike's dimensions
3. Prototyping and refining the design
4. Printing the final part with Nylon CF Slide and TPU
5. Intergration of 8 M6 brass inserts and 8 M4 brass inserts into to final print
6. Mounting and real-world testing during an actual ride

After a few adjustments, the mount proved strong, stable, and effective, offering the cyclist the aerodynamic setup they were after.

Budget-friendly without compromising

The ability to tailor the part to the bike’s exact geometry eliminated the need for any compromise - or expensive manufacturing alternatives.

To ensure the carbon handlebar remained undamaged, a TPU 95A layer was added. It required only minimal sanding for a smooth fit and provided extra protection during use.

Key takeaways

Here’s why this 3D printed aerobar mount is a win for cyclists and custom workshops alike:

Custom fit: Designed precisely for an unconventional setup – no compromises needed.

Durable & lightweight: Nylon CF Slide delivers strength and performance at a low weight.

Affordable innovation: Prototyping and final part production were cost-effective, even for a one-off solution.

Protection built in: The dual material combination of TPU and Nylon CF Slide adds a barrier between the mount and bike – no damage, no worries.

Pedal-powered innovation

This cycling application is a perfect example of how 3D printing can empower niche industries and passionate experts to create solutions where none existed before. Whether it's for prototyping, performance, or protection, UltiMaker technology keeps innovation rolling.