Case Study: Trek achieves production-quality, multi-material prototypes with Stratasys' Objet500 Connex3

Cutting-Edge Prototypes Push a Passion for Cycling

Trek Bicycle in Waterloo, Wisconsin needed prototypes that look and feel like production parts so engineers could validate fit, function and rider comfort across mixed materials (rigid frames, rubber grips, soft seats). To meet that challenge, Trek’s prototyping lab adopted Stratasys’ Objet500 Connex3 multi‑material PolyJet 3D printer, using Digital ABS and flexible materials to produce color, clear, tinted and rubber‑like components that closely mimic real production parts.

Using the Stratasys Objet500 Connex3, Trek now prints multi‑material assemblies in a single job—integrating durable Digital ABS with rubber‑like elements—eliminating material swaps and bonding steps, increasing uptime and speeding iteration. The result is more realistic, durable prototypes for functional testing (from chain guards and grips to pressure‑mapped seats based on finite‑element analysis), faster design decisions and more reliable on‑trail validation.

Trek

Mike Zeigle

Manager