Dirt Jumper V2: 3D printed in aluminum

Dirt Jumper V2, 3D printed almost entirely in aluminum by metal LPBF (laser powder bed fusion). It has the same geometry as the machined-junction version of V2: one frame, made two different ways. I used generative design for the head tube and bottom bracket junctions and TPMS lattices in the tubes, with CNC-machined dropouts. I proofed sections in polymer first and went from concept to an assembled metal prototype in under five months, working with an overseas print bureau.

Wolf Tooth displayed it at the MADE Bike Show in 2025, and it was also shown at Sea Otter Classic 2026. In early 2026 I converted it from chain to a Gates carbon belt drive. The belt was an afterthought in the design, so it didn't work as well as it could have, and I was still ironing out the kinks.