3D Printing –

DIY: More Canyon Computer Mounts …

November 30, 2025December 7, 2025 paschmann

One benefit of owning multiple Canyon bikes is that the majority of them have had the same style/shape of stem caps. From my very first one until now, I have printed, CNC’ed, laser cut, and layed up over a dozen, each with some unique design or nuanced variation depending on the manufacturing method. This version was no different 🙂 I have been waiting to streamline the design to have it fit closer to the bar profile on my MTB. So this time I set out to CNC a mold, wet lay carbon into the mold, and then CNC the shape.

Variant 1: Failed 🙁 the shape worked quite well but the finish was ugly and would be a nightmare to CNC accurately.

Variant 2: Failed 🙁 I CNC’ed the shape using Aluminum, wet layed the carbon, but it cured into the mold and was unable to demold it successfully with delaminating/damaging the part. read more

DIY: 3D Print – Speedmax Frame Insert

September 20, 2025September 19, 2025 paschmann

Another “fun”ctional 3D print for the Canyon Speedmax – there is a small cavity in the frame where the water bladder is inserted, if you dont use the bladder, this frame insert can hold some tools/tubes or small parts you may need during your ride. Its not a huge amount of space, but enough to be useful.

Designed in Fusion 360, printed in PLA.

DIY: Carbon Fiber Bottle Holder

August 30, 2025September 8, 2025 paschmann

Another carbon fiber project to design and create a bottle holder for behind the seat. 3D printed mould and used 8 layers of 220g 2K Carbon fiber for the wet layup.

DIY: Carbon Cockpit for Speedmax

August 3, 2025August 11, 2025 paschmann

My next foray into Carbon fiber design, tooling and development came with this project. Overall, a reasonable success. Still not perfect, and probably will not be used due to the catastrophic risk associated with riding a bike at 50mph and these breaking, but in theory and practice, a great learning opportunity.

Inspiration

DIY: Canyon BTA Mount

July 3, 2025August 5, 2025 paschmann

A bit of a clone from other designs on the market for a BTA bottle mount which has an adjustable angle. Made for the Canyon Speedmax. Printed, but not field tested, shortly after I switch to work on OpenAero designs.

OpenAero – A open source design system for Bike Accessories

May 11, 2025May 14, 2025 paschmann

After designing, building, rebuilding, and re-printing dozens of accessories for my bikes over the last few years, I wanted to create and share a open source design system for accessories for bikes that allows myself (and a community) to innovate and collaborate on these types of products. Here is a snippet from the readme file:

Our goal is to develop a modular mounting system for bicycle accessories — ranging from water bottle holders and lights to phone and cycling computers. Partially inspired by Gridfinity, this system provides a base platform and is intended to be stackable. The motivation behind the definition and open source nature of this project is to encourage community-driven design and innovation in the triathlon space. read more

Aero Bottle Cover

November 17, 2024December 23, 2024 paschmann

A fun 3D print to Carbon Fiber project.

Designed in Fusion 360, 3D printed a mould and did a wet layup in Carbon Fiber. Pretty happy with the way it came out and impressed it held up even on the really rough NZ chip sealed roads!

There was a lot of trial and error on this due to the deep cavity and needing a vacuum to hold the material in place.

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Gridfinity – Endurance Edition

November 15, 2024December 24, 2024 paschmann

Gridfinity is a great solution for 3D printing custom storage solutions. There is a “Gridfinity” layout for hundreds If not thousands of tools, home goods, workshop items, kitchen utensils, you name it … the best part is that if something doesn’t exist, you can pretty easily design and then 3D print it.

Gridfinity Catalog

I decided to take that challenge on since there are not many Gridfinity designs for smaller cycling or workout items, like the Garmin Varia, Drop sweat monitor, Core Body Sensor or Garmin Edge unit I have. Using the design reference and a super handy Plugin for Fusion 360, I designed and printed a bunch to keep my work space organized. Below are some images and the prototypes of the prints. read more

Carbon Fiber Arm Rests

October 27, 2024December 24, 2024 paschmann

This is my second pass at producing something strong enough and reliable enough to put onto my triathlon bike, and in this case some carbon fiber arm rests. My current arm rests pretty much did the job but at 300+g for the set, it seems like an easy win to reduce weight by making something similar out of CF.

The design for these took quite a lot of time, lots of trial and error and mistakes along the way 🙂 Cardboard cutouts, angles and long prints were the most tedious aspects, but ultimately I think they came out OK in the end.

Ideation and prototyping Steps

DIY – “Forged” Carbon Fiber

October 13, 2024December 24, 2024 paschmann

After having some reasonable success in #D printing moulds and doing some layup in CF, I thought I would attempt a “forged” CF version of a part I have 3D printed in the past. Unfortunately it didn’t quite go according to plan, it ended up weighing close to 4 x more than the basic version. A fun experiment none-the-less!