August 7, 2024 3D printed components virtually eliminate material waste
Bluesign accredited, Green Button and ClimatePartner certified Deuter’s Hiline Enduro backpack features an impressive smattering of sustainability credentials. Yet could its 3D printed components be the real game changer?
Full speed downhill on rugged singletrack, big air at the bike park, and speeding round berms like enduro biking is lots of fun. But it also takes its toll on riders and their gear too. So mountain bike backpacks for enduro need to be durable and reliable. The new Hiline downhill riding combines the latest 3D printed Airstripes back system with a snug, compact fit, and spine protection setting the bar high when it comes to both safety and functionality.
German backpack pioneer Deuter worked together with its Pro Team members to analyze what makes a good enduro backpack that can handle the most challenging conditions. And the new Hiline is the result. When it came to product development, safety first was the priority. Whether it’s jumps or riding slippery, gnarled tree roots, taking a spill is not out of the question. By teaming up with Oechsler, a leading polymer technology company, Deuter has come up with the back system of the future. Based on its proven Airstripes back system, the foam element is now replaced with a 3D printed, open-cell structure made from EPU.
This has multiple advantages in terms of both sustainability and performance.
Compared to previous methods, where off-cuts lead to substantial material waste, the precise nature of 3D printing technology cuts material waste down to maximum 3%.
“To explain it simply, the liquid resin (our material) hardens under UV light, the resin is printed (or hardened) by projecting the respective layer onto the metal plate at the top and thus is exposed to UV light – and a new layer is created,” explains Benedikt Schöps, Product Manager Bike at Deuter.
“The great advantage really is that you can implement different densities and structures into one part/component and thus adopt the part perfectly to its purpose and create different zones with different functionalities within one part. Where with foams for example (which are often used as alternatives) you need to layer and cut them in order to achieve such functionality and therefore end up again with more loss or left overs.”
The body fabric is recycled, and this bluesign® accredited product is Green Button certified and ClimatePartner certified. And naturally, none of the materials contain any per- and polyfluoroalkyl substances (PFAS).
3D printing also a performance win
The memory foam back protector that was previously built into the pack has been replaced with a narrower, lighter weight TÜV and GS certified spine protector that molds to the shape of the back and offers more focused multi-impact protection. Following a crash, the protector automatically returns to its original shape. An impact does not damage the protector, and it can be used again.
When it comes to bumpy trails and cross-country, the second most important aspect aside from protection is a good fit. And this is where the Hiline also shines. The EPU material of the back padding molds precisely to the shape of the back and, combined with the vest-style shoulder straps and the adjustable elastic sternum strap and waist belt, creates a wrapping fit that doesn’t compromise balance.
The new Airstripes back system has spaces between the padding for ventilation. And the new 3D-printed back pads are also more air permeable than ever to keep air moving across the back. So on top of providing reliable protection, a comfortable carry, and improved ventilation, the 3D printer technology used for this latest innovation in back systems also cuts down weight. Combined with the use of lightweight materials and an overall reduction in materials, the result is outstanding comfort for the weight.
Given its combination of performance and sustainability, Benedikt Schöps sees a promising future for this technology’s wider adoption:
“Generally speaking, the material and the technology can be used everywhere where constant pressure is applied – such as the backsystem (which we did in the Hiline), in the hip fins/belt or lumbar pads especially in larger backpacks, e.g. for trekking or thru-hiking, or maybe even in shoulder straps – though this has yet to be tested.”
And then there is also the potential of nearshoring supply chains:
“Our partners at Oechsler are located in Ansbach, Bavaria, which is located approx. 115km north of our headquarters in Gersthofen, Bavaria. The pads were developed and are also printed there. So, we had rather short distances in the development process with Oechsler, which we appreciated.”
Photo: Deuter
