Case Study: Kalkhoff achieves a fully functional metal 3D‑printed e‑bike frame in six weeks with Materialise

Materialise Delivers Fully Functional Metal 3D-Printed Bike Frame to Kalkhoff Within Six Weeks

Kalkhoff, a German bike manufacturer with over 100 years in the industry, needed a fully functional metal prototype of a new e‑bike range that would match final geometry, accept real add‑ons, and withstand their rigorous load testing (about 170 kg). They turned to Materialise, leveraging Materialise’s metal 3D‑printing capabilities (aluminum printing from its Metal Competence Center and use of Materialise Manufacturing services) to move beyond plastic prototypes that couldn’t deliver realistic function tests.

Materialise worked with Kalkhoff to optimize the CAD, 3D‑print the multi‑part aluminum frame, and coordinate welding and two‑step heat treatment with local partners, delivering a rideable prototype within six weeks. The result: a fully functional aluminum frame that passed Kalkhoff’s 170 kg dynamic test, cut roughly three months from the development timeline, enabled realistic assembly and event demos, and accelerated design iteration—demonstrating Materialise’s impact on speed, quality, and testability.

Kalkhoff

Rik Maes

Industrial Designer