From Concept to Reality: Prototyping a Custom Swingarm with 3D Printing

How 3D Printing Helped Prototype a Custom Triumph Bonneville T100 Swingarm

At Briggs & Davis, we thrive on solving complex challenges with innovative solutions. When Justin approached us with his vision for a fully custom Triumph Bonneville T100, he needed a way to create a functional swingarm prototype—quickly, affordably, and without compromising on quality. By combining the precision of FDM 3D printing, the speed of rapid prototyping, and the accuracy of advanced CAD modeling, we were able to bring his vision to life.

The Challenge: Designing a Large-Scale Swingarm

Creating a 52cm swingarm for a custom motorcycle wasn’t a straightforward task. The component had to meet specific design and structural requirements while also being manufacturable on a limited budget. Justin’s goal was to test the swingarm’s fit and function during the prototyping phase, but traditional manufacturing methods like CNC machining were too costly and time-intensive.

Arthur stepped in to design a solution that overcame these hurdles while ensuring the prototype could be refined and tested before moving into full production.

The Process: Combining Advanced Technologies

The first step was leveraging our CAD modeling to design a precise digital representation of the swingarm. This allowed Arthur to map out the necessary geometry, structural features, and connection points for assembly. Given the size of the swingarm, printing it in one piece wasn’t feasible. Instead, Arthur designed a unique joinery system that allowed the swingarm to be printed in sections and then assembled seamlessly.

Using FDM 3D printing, we then produced each section with high accuracy, using a high quality PLA with high infill settings to ensure the prototype could withstand functional testing. This approach allowed us to minimize waste and avoid the lengthy setup times associated with traditional manufacturing.

Why Rapid Prototyping Was Key

By employing rapid prototyping, Justin was able to evaluate the swingarm’s design within days instead of weeks. The iterative nature of this process made it easy to adjust dimensions, test connections, and refine the overall design. This saved significant time and money compared to traditional methods, where even minor adjustments can result in costly delays.

Thanks to the combination of 3D printing technology and our tailored design approach, Justin could confidently move forward with his project, knowing his prototype was functional and production-ready.

The Outcome: A Refined Prototype and a Step Forward

This project highlights the power of integrating advanced design tools and modern manufacturing techniques. By using FDM 3D printing for this swingarm, we proved that even large and complex components can be prototyped quickly, accurately, and affordably.

If you’re looking to develop your next big idea, Briggs & Davis is here to help. From rapid prototyping to innovative design solutions, we turn ambitious concepts into tangible results.