3D printing for cyclists: custom parts and accessories

3D printing for cyclists: which parts and accessories can be printed to order

Sooner or later every cyclist needs a part that isn’t in the shops. A handlebar end plug breaks, a standard bottle cage doesn’t fit, and the light mount was discontinued long ago. 3D printing solves these problems: you can make any part exactly for your bike, with your specific dimensions and wishes in mind.

In this article we look at the most popular bike accessories printed on a 3D printer and explain which materials work best for riding in different conditions.

Popular bike accessories for 3D printing

Handlebar mounts for phones and GPS units

Probably the part cyclists ask for most. Factory mounts are often unreasonably expensive, and universal ones don’t hold a phone securely on rough roads. A 3D-printed mount is designed for a specific smartphone model and your handlebar diameter. The result is a snug fit with no play or unnecessary vibration.

For Garmin, Wahoo and other GPS units, you can print adapters that work with the brand’s quarter-turn mount but fit non-standard stems or handlebar bags.

Derailleur guards

The rear derailleur is one of the most vulnerable parts of a bike. It’s easily damaged in a fall or in transport. A 3D-printed guard (or hanger protector) takes the hit and costs much less than repairing the derailleur. These parts are usually printed in tough materials that can withstand impacts and won’t break at the first contact with an obstacle.

Cages for non-standard bottles

Standard bottle cages are designed for 73 mm bottles. But what if you use a wider insulated bottle or want to fit a bottle on the down tube where space is tight? 3D printing lets you make a cage exactly for your needs — taking into account the bottle diameter, the mounting point and the angle.

Light brackets

Bike lights often come with their own mounts, but they’re not always compatible with your handlebar or seatpost. 3D-printed brackets solve this: you can make an adapter for any tube diameter and any light model. This is especially relevant for those who use powerful hiking torches instead of dedicated bike lights.

Chain guard

A chain guard keeps clothes out of the drivetrain and keeps your trousers cleaner. For many city and touring bikes, factory chain guards are either unavailable or the wrong size. A 3D-printed chain guard is made to the measurements of your frame and chainrings, so it fits perfectly without extra adjustment.

Custom handlebar end plugs

It seems a small thing. But open handlebar ends are dangerous: in a fall the tube can cause a serious injury. Plugs also keep moisture and dirt out of the handlebar. 3D printing lets you not just close the ends but add a personal design — a team logo, initials or any other image.

Tool organisers

A multitool, patches, tyre levers, a spare inner tube — all of these need to be to hand but not rattling around in a backpack. A 3D-printed organiser mounts under the saddle, on the frame or inside a saddle bag. Every tool has its place; nothing rattles or gets lost. The organiser can be shaped around your particular tool set.

Mounts for GoPro and action cameras

Filming rides is growing in popularity, and standard GoPro mounts don’t always give the viewing angle you want. 3D-printed brackets let you fit a camera on a helmet, the handlebar, the seatpost or even the fork — at any angle. The adapters are compatible with the standard GoPro mount, so the camera is easy to remove and refit.

Which materials to choose for bike parts

The choice of material is key to how long a printed part lasts. Bike accessories work in harsh conditions: sun, rain, vibration and temperature changes. So not every plastic will do.

PETG — the main choice for outdoor use

For most bike parts we recommend PETG. This material combines several important properties:

• UV resistance — the part doesn’t degrade from long exposure to sun, doesn’t yellow or become brittle
• Mechanical strength — it withstands loads, impacts and constant vibration while riding
• Moisture resistance — it doesn’t absorb water or deform in rain and humidity
• Chemical resistance — it isn’t damaged by chain lube and other bike products

PETG is the best choice for mounts, brackets, protective parts and holders. Read more about material properties on the 3D printing materials page.

TPU — for parts that absorb vibration

For parts where elasticity and cushioning matter, TPU — a flexible plastic — is used. It’s ideal for:

• Damping pads between the phone mount and the handlebar — they absorb vibration and protect the screen
• Protective frame pads — where cables rubbing leave scratches
• Elastic light straps — they grip the tube gently without damaging the paint
• Shock-absorbing handlebar end plugs

Often the best result comes from combining materials: the main structure in PETG and the contact parts in TPU. You’ll find a comparison of different plastics in the article PLA vs PETG vs TPU.

How to order 3D-printed bike parts

Ordering is simple. If you have a ready-made 3D model (for example, downloaded from Thingiverse or Printables), send it to us and we’ll print the part in the material and colour you need. No model? We’ll tell you where to find a ready-made one (on Printables, Thingiverse or MakerWorld) or who can make it.

A few tips before ordering:

• Measure the diameter of the handlebar or frame tube where the part mounts — this is critical for an accurate fit
• Photograph the mounting location from several angles
• Tell us whether the part will be outdoors all the time — this affects the choice of material
• If the part has to connect to factory components, send photos of them with a ruler for scale

Advantages of custom 3D printing over off-the-shelf accessories

Off-the-shelf accessories are designed for an average bike. But every bike is unique, especially if it’s built from different components or has non-standard frame geometry. 3D printing gets you a part that fits your bike perfectly, without compromises or adapters.

And if a part breaks or wears out, it can be reprinted in a few hours from the saved 3D model. No need to wait for delivery from abroad or hunt for alternatives in the shops.