3D printing a geometry optimized BMX sized bike frame at home

Additive manufacturing, namely filament 3D printing, is becoming a widely used technology in the consumer space. But how far can 3D printing with consumer materials at home go? This thesis sets out to answer this question by 3D printing a BMX sized bike frame. The design of the frame had to balance rigidity and weight while ensuring sufficient strength to be ridable. Generative design was the optimum method to achieve this. Furthermore, 3D printing techniques like nozzle diameter, print orientation and filament types were analysed, so that the strongest combination of part geometry and 3D printing technique could be developed. As large form factor 3d printers are not available in the consumer space, a CNC mill was modified into a 3D printer large enough to produce a small bike frame.