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Bastion launches 3D printed integrated cockpit system

Will Strickson
10 May 2021

Australian custom builder uses combination of 3D printed titanium and carbon fibre to create a beautiful setup you won't find anywhere else

Bastion Cycles has revealed its new integrated cockpit system made from a combination of 3D printed titanium and carbon fibre.

The Australian custom bike builder, the only bicycle company in the world with in-house titanium 3D printing, unveiled the development at the Handmade Bicycle Show Australia, showing off the super clean internally routed fork and one-piece bar-stem.

This addition to its repertoire not only looks fantastic but Bastion says it also allows for optimised handling and ride quality for each rider.


Ben Schultz, Bastion managing director, said, 'When we are designing a custom bike for someone, fork offset and head tube angle are two of the most important variables in getting the bike to handle the way we would like and the customer expects.

'The new cockpit and the addition of our breakthrough technology to the fork and bar stem extends the same beautifully refined and smooth ride quality to the front of the bike, matching the rear.

'The icing on the cake has been the ability to hide all the hoses and wiring which is something customers are increasingly asking for as it creates a much cleaner aesthetic and also delivers a small aerodynamic advantage.'

In order to achieve this, Bastion has created a new process to build the crossbar, fork legs and steerer using hard tooling and pre-impregnated carbon fibre.


Bastion also says that alongside handling and aesthetic improvements, the NACA foil shapes of the fork legs and crossbar – along with having an integrated system – boost the aerodynamic efficiency of its bikes.

Engineering director James Woolcock said, 'We really tried to balance adding some aerodynamic benefits with the overal aesthetics and are extremely happy with where it has ended up. We definitely feel it achieves that optimal condition of satisfying both form and function.'

The components will also go through extensive quality control using ultrasonic testing by world renowned expert Raoul Luescher from Luescher Teknik to ensure maximum safety (and quality) of its parts.


Components and features

Bastion is a pioneer in 3D printing and uses Grade 5 Titanium Alloy for its parts. The new cockpit consists of three main parts.

Firstly the fork, which has 3D printed titanium crown and dropouts alongside carbon fibre legs and steerer tube. For integration purposes Bastion has used a D-shaped steerer and matched that with a D-shaped bore in the stem. The bar stem consists of 3D printed titanium stem and drops with a single piece carbon fibre crossbar.

Finally there is also a 3D printed titanium compression plug bonded into the steerer that reduces the risk of damage to the steerer as a result of over-tightening.

Dimensions of the system can be completely customised for the rider thanks to the ease of 3D printing to maximise comfort, efficiency and aerodynamics.

Find out more about Bastion Cycles at and if you're interested in buying one for yourself visit Bastion's UK partner, Velo Atelier, at

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