Bicycle Brake Caliper

From Appropedia
About this device
Bicycle Brake Caliper Print.jpg
Keywords 3D printing, bicycle, brake caliper
Uses transportation, hobbyism
Authors Albert Cowsky
Status Prototype
Made? Yes
Replicated? No
Designed in United States
Affiliations MOST
Materials Plastic
Cost USD $ 2.29
SDGs SDG09 Industry innovation and infrastructure
License data
Hardware CC BY-SA 4.0
Instructions data
Manufacturing files
Translation data

Bicycle Brake Caliper[edit | edit source]

Project developed by Albert Cowsky

Abstract[edit | edit source]

Brake Calipers are an important component required to build a bicycle. In order to build a cheaper, open source, bicycle, the calipers can be printed and fitted with brake pads. Open source bicycles could reduce the cost of transportation for people that cannot afford to buy a commercial bicycle. This project can be combined with others to make a largely cheaper and printable bicycle.

Bill of Materials[edit | edit source]

(Makes Two Calipers)


Commercial Parts

Tools needed[edit | edit source]

Skills and knowledge needed[edit | edit source]


Technical Specifications and Assembly Instructions[edit | edit source]

(I do not currently have all the necessary materials so they will not all be shown here. I will update this in the future if I get a chance to actually implement it.)

Print time = 3 hours per caliper. 6 hours total

Bicycle Brake Caliper Print.jpg

Assembly time = approximately 15 minutes

Bicycle Brake Caliper Assembled.jpg

  1. Remove parts from the print bed
  2. Attach the base of the calipers to the fork of the bicycle with bolts.
  3. Use a washer on the far side before putting the nut on.
  4. Install brake pads into inward facing cylinders.
  5. Connect the cable guide receiver to the right caliper with a bolt.
  6. Put the cable guide into the receiver.
  7. Run a bolt backwards through the top of the left caliper.
  8. Add a washer and screw the nut most of the way on.
  9. Adjust the brakes so there is only a small clearance (~3mm) between the brake pads and the wheel wall.
  10. Wrap the brake cable around the bolt underneath the washer.
  11. Tighten the nut down to secure the brake cable.

Common Problems and Solutions[edit | edit source]

  • Brake line comes loose
    • Ensure that the bolts are still properly tightened every few weeks

Cost savings[edit | edit source]

  • Total Cost (two calipers) = $19.60
    • Commercial Component Cost = $17.31
    • Plastic Cost - 99.4g (49.7 each) at $23/kg = $2.29
  • |Commercial Calipers
    • $16-$40 each
    • $32-$40 for two
  • $12.4 - $20.4 savings for two calipers
  • 38.75% - 51% savings

References[edit | edit source]