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Unleashing the Potential of 3D Printing for E-Bike Prototyping and Tooling

Nov 9, 2023

Comosworks Ltd. was established on December 24, 2021, and is based in Hangzhou, China. They mainly provide services such as e-bike sales, repair, spare parts sales, technical services, technology development, mechanical parts, etc. The enterprise’s slogan is “It’s Never Just A Ride”, and their vision is to let more people embrace the infinite possibilities of life through cycling.

Comosworks used the Raise3D Pro3 Plus printer to print large-scale fixtures


A More Cost-efficient Alternative to Traditional Tooling

Due to the increasing cost and time of traditional manufacturing methods, 3D printing has been gaining traction as an alternative process to create bicycle parts, such as brakes, gears, and supports, etc. 3D printing has several advantages that traditional manufacturing can’t offer. It is faster, cheaper, and more customizable, which allows manufacturers to produce complex and intricate parts at a fraction of the cost and time of traditional methods.


Based on this, Comosworks decided to use 3D printing to replace the traditional process, and after doing thorough research on 3D printing, they saw the potential and chose Raise3D’s Pro3 Plus and E2CF to produce prototypes and tooling for testing during the development phase of the e-bike, enabling them to save delivery time and improve the success rate of prototype verification.

Great efficiency and precision on prototype making


Greater Customization in Terms of Materials, Size, and Shape

Currently, the Comosworks team uses PLA and PA CF as the main materials for printing. It is worth mentioning that Raise3D Pro3 Plus and Raise3D E2CF are paired with Raise 3D’s slicing program, ideaMaker. This platform has an Open Filament Program (OFP) that works with the best 3D printing filament manufacturers to provide different filament templates, aiming to enable customers to pick the best profile according to their needs and preferences and therefore achieve the best printing effect and ultimately create more than you ever thought possible!


The use of a jig or fixture is a very important part of the manufacturing process as it provides added accuracy and uniformity to the products produced. The Raise3D E2CF printer is optimized for 3D printing carbon fiber reinforced filaments and is durable, user friendly and stable in operation, thus providing accurate print results. What’s more, Raise3D E2CF has a flexible build plate, which allows 3D printed parts to be easily removed, while minimizing potential damage to the part during removal. The Raise3D E2CF printer plays an important role in the manufacturing of jigs and fixtures.

Raise3D E2CF is working on jigs and fixtures


Produce Parts with Higher Accuracy and Greater Repeatability

Prototyping is a crucial part of the product development phase. According to the feedback from Comosworks staff, before the application of 3D printing, the traditional CNC method of making prototypes usually took weeks and months, and once the prototype was made but still needed to be modified, it was about to be another long waiting process. After using 3D printing, the Raise3D Pro3 Plus works up to 20h per day at full capacity and produces 10 model parts and 10 mass production parts in a week. Additionally, Raise3D Pro3 Plus eliminates the need for tooling, which results in even greater savings on production costs and allows manufacturers to rapidly prototype new parts and components without needing to invest in expensive tooling.

Two fixtures created are applied to Model A and Model R


Allow for Large Build Area and Rapid Product Iteration

With a large build volume of 11.8 x 11.8 x 23.8 inches (300 x 300 x 605 mm) when printing with a single printhead and 10 x 11.8 x 23.8 inches (255 x 300 x 605 mm) in dual printhead mode, the Raise3D Pro3 Plus printer can accommodate larger models and print these large models in a single pass, significantly reduce the cost and time of large builds. Meanwhile, having a <1 second switch time means the Raise3D Pro3 Plus can change directions while printing an object and this shortens the overall time needed to complete a 3D printing process.

Raise3D Pro3 Plus


3D Printing will Go Further in the Field of E-bikes

The application of 3D printing technology in the electric bike industry has great potential for revolutionizing the production process. By utilizing this technology, companies can produce components faster and more cost-effectively. It also reduces the need for assembly and tooling, and enables the production of parts with intricate designs. According to Comosworks staff, “After using the Raise3D printing, we have avoided the long cycle of outsourcing and modified the design in a timely manner“. Ultimately, 3D printing offers great benefits to companies looking to produce faster, lighter, and more energy-efficient electric bikes.

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