Case Study: 2Stroke Stuffing achieves a record-breaking engine build with Protolabs DMLS 3D printing

2Stroke Stuffing - Customer Case Study

2Stroke Stuffing, led by Alex Degnes, set out to build the world’s most powerful two-stroke engine and break the 50cc speed record at Bonneville. After trying investment casting and finding it limited by porosity and design constraints, the team needed a way to create a more complex, lighter, and better-cooled cylinder for the superbike.

Protolabs provided a DMLS 3D-printed AlSi10Mg aluminium cylinder, helping turn the design into a manufacturable part in just a couple of days. The result exceeded expectations, with Alex praising the fit, quality, and speed of delivery; Protolabs’ rapid turnaround was even faster than shipping a part from Norway, supporting the build of a more powerful engine aimed at exceeding 100 mph.

2Stroke Stuffing