3D Printed Bike Parts: Custom Aerobar Mount on UltiMaker S8

For specialist bike workshops, 3D printed bike parts solve a problem off-the-shelf hardware cannot. Pim van der Marel runs Wielerhuis Marel, a workshop in the Netherlands. A customer came in with a request: fit aerobars to a road bike with a carbon handlebar no standard mounting hardware would grip.

"This problem couldn't be fixed before," Pim says. "There was no existing solution that fit."

So Pim turned to additive manufacturing.

Why off-the-shelf hardware did not fit

The handlebar geometry was bespoke. Standard aerobar clamps were not made for the cross-section. Compromising the bike was out. The customer wanted the carbon handlebar untouched. Buying short-run tooling for a one-off part made no commercial sense.

3D printed bike parts make the maths different. A workshop with a printer designs a fit-to-purpose solution in hours, not weeks. Cost stays low even on quantity one.

Dual extrusion on the UltiMaker S8: TPU 95A meets Nylon CF Slide

The UltiMaker S8 is built around an open material system and a dual-extruder head. Pim paired two engineering filaments in the same print.

Nylon CF Slide handled the structural mount and bridge. It is strong, light, and dimensionally stable. TPU 95A formed the contact layer between the mount and the carbon handlebar. It is flexible, abrasion-resistant, and gentle on a high-value bar.

For prototyping, Pim ran PLA on the same printer to test fit before committing to engineering material. Open-material printing gives you rapid iteration and final-part production on one machine. The UltiMaker S8 overview covers the full specifications.

From sketch to ride: the build process

The workflow was lean:

1. Brainstorm the concept

2. Measure the bike's exact dimensions

3. Print a PLA prototype to confirm fit

4. Print the final part in Nylon CF Slide and TPU

5. Integrate eight M6 brass inserts and eight M4 brass inserts into the final print

6. Mount the assembly and ride-test it on the road

The mount was strong, stable, and aerodynamically sound on the first ride. Pim made small adjustments. Then he handed the bike back to the customer.

Built-in protection for the carbon handlebar

The carbon handlebar was the highest-risk surface in the build. A hard plastic clamp would mark it. The TPU inner layer solved the issue. After minimal sanding, the soft-touch interface sat flush against the carbon and absorbed contact load during use.

What this means for Australian workshops

Australian bike shops, motorsport teams, and custom fabricators face the same problem every day. A customer brings in a part nobody makes. Most workshops outsource the design work or turn the job away. With a capable benchtop printer and a small library of engineering filaments, the same shop offers custom 3D printed parts as a service.

The broader pattern applies to defence prototypes, automotive jigs, and short-run replacement parts. Where a single mould would cost more than the project, a printer pays back in weeks.

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Frequently asked questions

Can you 3D print bike parts?

Yes. With engineering filaments such as Nylon CF Slide, PETG, or carbon fibre composites, 3D printed bike parts handle real-world stress for mounts, brackets, and accessory hardware. They are not a substitute for safety-critical structural components such as forks or frames.

What is Nylon CF Slide used for?

Nylon CF Slide is a carbon-fibre-reinforced nylon filament. It delivers high stiffness, low friction, and good wear resistance. Common uses include mechanical brackets, bushings, and tooling parts where strength matters and weight is a constraint.

Is the UltiMaker S8 good for dual material printing?

Yes. The S8 has dual extruders and an open material system. You pair structural filaments such as Nylon CF Slide with flexible filaments such as TPU 95A in the same print. The combination suits multi-material assemblies and one-off custom parts.

Can TPU protect carbon fibre components?

Yes. TPU 95A is a flexible, abrasion-resistant filament. As an interface layer between a 3D printed mount and a carbon fibre handlebar, it absorbs contact load and prevents scuffing or stress concentrations.

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Bring custom parts production into your shop

Pim turned a job most workshops would refuse into a satisfied customer. The same workflow is open to any Australian shop with a capable benchtop printer and a willingness to design the solution. Get in touch with our team to talk through dual-material 3D printed bike parts on the UltiMaker S8.

Want to view the full UltiMaker range? Click here.

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3D Printer 3D Printers additive manufacturing Custom bike printing Custom printing Manufacturing Nylon TPU 95A UltiMaker ultimaker s8