How Ridley Bikes benefits from Additive Manufacturing

The recently introduced Triton Fast is the latest innovation from Belgian bicycle manufacturer Ridley Bikes. It is a pure triathlon bike, developed in close collaboration with top athletes such as world champion Jelle Geens.

One of the key strengths of the Triton Fast is its low aerodynamic drag, which has been refined down to the smallest detail – from the frame tubing to the innovative integrated hydration and storage system.

This integrated hydration and storage system is modular and consists of separate compartments for fluids, nutrition, tools and waste. The design of these compartments has been optimised to ensure that aerodynamic airflow is not disrupted. The hydration system runs through a tunnel inside the frame, allowing triathletes to drink while remaining in a full riding position, resulting in valuable time savings.

From concept to functional parts

During the development and testing phase, Ridley selected Tenco as its partner for producing the first functional components. Tenco was responsible for the final design of the components, including the mounting system.

The top tube packs — consisting of a compartment for protein bars and a small waste pouch — as well as a larger storage compartment for items such as small tools, were 3D printed in a rubber-like material. The hydration compartment was produced using PET-G material.

Thanks to the rapid iterations made possible by 3D printing, functional testing could be carried out quickly and efficiently.

Efficient go-to-market

Following the successful introduction of the Triton Fast, injection moulding was selected as the final production technique for the top tube packs. Due to their complexity, the hydration packs continue to be produced using 3D printing.

This also allows Ridley Bikes to order in variable quantities without committing to minimum order quantities (MOQs). As a result, order sizes align more closely with actual demand, helping to minimise inventory investments.

Another economic advantage is the absence of upfront investments in tooling or production set-up, resulting in lower capital commitment and reduced risks such as premature tooling depreciation.