The redesigned one-piece Lotus 110 saddle clamp produced with metal 3D printing.

Image source: @Mavic_3G

I’m Paul, a cycling enthusiast since my student days and the person behind the @Mavic_3G account.

On bikes from the 70s and 80s, most parts were forged or cast. These are magnificent processes, but they are highly energy-intensive and require specialized tooling, making the manufacturing of such components particularly complex today. That’s where 3D printing comes in.

Recently, I had the opportunity to recreate the saddle clamp for the legendary Lotus 110 (the road version of the iconic Lotus 108).

In 2021, Lotus and Hope released a new track frame utilizing aluminum and titanium 3D printing. Thirty years after the 108, techniques have evolved, so why not apply this modern technology to its big brother, the 110? I chose to work on this project with IN3DTEC.

This clamp was the perfect candidate.

Originally, the part was assembled from a bent component and a welded addition. Thanks to additive manufacturing, it is now designed as a single, solid piece, which greatly simplifies production while pushing the boundaries of design.

CAD design showing how the original multi-part component was re-engineered into a single-piece structure.

Image source: @Mavic_3G

With metal 3D printing, it becomes possible to rethink traditional components and create designs that would be difficult to manufacture with conventional methods.

One of the most interesting parts of this project was transforming a multi-part component into a single design.

Instead of relying on separate parts and welding processes, the saddle clamp can now be produced as one solid component. This not only simplifies production but also opens new possibilities for custom bicycle parts and engineering projects.

The top view reveals the internal geometry made possible by metal additive manufacturing.

Image source: @Mavic_3G

Original multi-part welded assembly compared with the redesigned one-piece 3D printed clamp

Image source: @Mavic_3G

 A close-up of the smooth glass bead-blasted finish applied to the metal saddle clamp.

Image source: @Mavic_3G

For the finish, I opted for glass bead blasting, a much gentler method than traditional sandblasting, which is ideal for achieving an impeccable surface finish without altering the material's structural integrity.

Beyond the technical aspects, it’s the entire process leading up to the final result that fascinates me.

It allows a finished product to be created very quickly and brings to life projects that might otherwise seem impossible for hobbyists. With technologies like metal 3D printing and the support of IN3DTEC, ideas that once required complex tooling and production methods can now become real, functional parts in a much shorter time.

The 3D printed metal clamp mounted on the seatpost for functional testing

Image source: @Mavic_3G

Side view showing the fit between the redesigned clamp and the aerodynamic seatpost profile

Image source: @Mavic_3G

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Have a custom part in mind? Bring your idea to life with IN3DTEC’s metal 3D printing services.Upload your CAD files HERE now.