New York State based titanium specialist brand No.22 has introduced the world’s first 3D-printed titanium aero bike, named the Reactor Aero. This frameset utilizes a combination of 3D printing and in-house fabrication processes to create an aerodynamically optimized profile exclusively from titanium, setting it apart from other titanium framesets on the market.
The Reactor Aero is an evolution of the brand’s existing race bike, the Reactor, with the new Aero version undergoing computational fluid dynamic (CFD) analysis during the design process. Although the bike has not yet been tested in a wind tunnel as of the announcement date, No.22 has confirmed that this will occur before the commercial launch in 2025.
According to the results of the finalised frameset’s CFD simulations, the Reactor Aero is projected to offer approximately a 30-40% reduction in aerodynamic drag compared to the brand’s all-road bike, the Aurora.
The Reactor Aero is very angular in its aesthetic with the frameset able to accommodate up to 34mm tyres (Image credit: No.22)
The Reactor Aero, while designed for speed, offers flexibility with space for up to 34mm tyres, allowing riders to choose more forgiving or adventurous options.
In addition to aerodynamics, No.22 focused on improving drivetrain stiffness with the Reactor Aero. The brand claims that these enhancements make the Reactor Aero frameset the most efficient in terms of power transfer among titanium frames.
This was achieved by redesigning key areas of the frame such as the down tube, bottom bracket intersection, and chain stays to optimize power transfer using 3D printing technology. The brand also mentions that other tubing profiles and intersections were redesigned to balance drivetrain stiffness with the renowned ride quality of titanium.
The Reactor Aero has improved power transfer stiffness by redesigning key areas of the frames tube profiles. (Image credit: No.22)
The prototype displayed at the MADE bike show is a fully 3D printed frame using Grade 5 titanium powder, except for the seat post which is made of carbon fiber. The integrated seat post features an aerodynamic profile and is a collaboration with July Bicycles.
The final version of the Reactor Aero will be manufactured in multiple sections that will be machined and welded together in-house. This approach allows No.22 to maintain quality control over the manufacturing process, ensuring high-quality finishes and tolerances.
The only part of the Reactor Aero that is not made of titanium is the carbon fibre integrated seat post that is made in collaboration with July Bicycles. (Image credit: No.22)
Bryce Gracey, a Co-Founder of No.22, stated in a press release, “3D printed titanium has phenomenal structural properties. The ability to print internal support structures anywhere in the frame gives us a level of control over the ride quality that has not been possible before.”
“We are able to add stiffness in high load areas like the bottom bracket, dropouts, and head tube for very little weight while playing with structure in fine detail throughout the frame to ensure it delivers the ride quality we need.”
Pricing and availability
Pricing details for the Reactor Aero are not yet available. However, given that the standard Reactor frameset retails for $6,499 and complete builds start at $12,015, the Reactor Aero is expected to be positioned as a high-end dream bike for enthusiasts. No.22 anticipates releasing the Reactor Aero in 2025 with more information forthcoming.
