Bicycle Taillight Adapter

A system of mounts for bicycle taillights, designed by Sintesi Labs for a specialist in high-end road and gravel bikes, needed to be technically developed and implemented.

In doing so, it was necessary to take into account both the customers’ high expectations regarding material efficiency and aesthetics, as well as the requirement to be able to produce the products as specially customized small batches using additive rapid prototyping.

Team

Brandes

Services

Concept Modeling
Solid Modeling
DFM (Design for Manufacturing)

Software

FreeCAD

Complexity

S

3D modeling for additive manufacturing

The adapter is designed to allow existing battery-powered taillights to be mounted on the seat stays as an alternative to the manufacturer’s provided seatpost mounting.

To do justice to the exclusive nature of this limited-edition series, production was to be carried out using STL 3D printing. In the first step, the position of the taillight and the optimal mounting mechanism were developed through several design iterations.

The 3D model was then optimized to meet the requirements of the additive manufacturing process, such as stability, slicing, and support structures.

By structuring the model as a parametric dataset, it is possible to adapt rear light mounts from different manufacturers to seat posts of various designs with relatively little effort, thereby enabling a customized “built-to-customer” product.

case studies

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