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Bike Thru Axle

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MOST Delta filament as guide.JPG This page was part of an MTU course MSE4777 OA and MSE4777 OB/MSE5777/EE4777/EE5777: Open-source 3-D printing

Please leave comments using the discussion tab. The course runs in the Fall semester. It is not open edit.

Bike Thru Axle[edit]

Project developed by Jnbart (talk) 06:32, 5 December 2019 (UTC)
This OSAT has been designed but not yet tested - use at own risk.
This OSAT has been prototyped.

You can help Appropedia by contributing to the next step in this OSAT's status.


  1. This OSAT Project helps multiple goals, primarily goal 10 by helping to make bike transportation more accessible and to decrease the cost and increase the ability to repair a bike that has a broken axle. This part was designed to replace the original axle on my 2017 Raleigh Tokul 3 mountain bike, but could easily be modified to fit any "Thru" style bike axle.
  2. This part features a hollowed center section to reduce the material used in the print, and otherwise uses a 75% infill for strength. The first iteration used a 50% infill, and due to that and a misplaced thread relief, it was not able to withstand the abuse of being ridden hard. The current model has been ridden and tested thoroughly, and has survived numerous hash riding conditions.
  3. To further increase the durability of this part a higher infill percentage could be used, and to increase the usability a Hex keyway in the threaded end of the shaft would allow for the axle to be properly torqued more easily.
Final Print
Design Iterations
First vs Final
Axle Installed for Testing
Axle Installed for Testing

Bill of Materials[edit]

  1. 22 Grams of PLA Filament
  2. Part Files (Which can be found here: [1])

Tools needed for fabrication of the OSAT[edit]

  1. MOST Delta RepRap or similar RepRap 3-D printer
  2. M12-1.5 Die to cut threads in the end of the shaft

Skills and Knowledge Necessary to Make the OSAT[edit]

  • 3D printing basics
  • How to use a Die to cut threads

Technical Specifications and Assembly Instructions[edit]

  1. Axle was printed with PLA with the length of the shaft in the Y direction
  2. Printed at 215C and a heat gun was used to preheat the bed to reduce warping
  3. Print Time: 1 Hour 46 Minutes with a 60mm/s print speed
  4. After print is complete some minor filing/sanding may be required to ensure a tight fit to the hub and bearings
  5. Use the die to cut threads on the end of the shaft. Do not cut them any farther than you need, as this will reduce the overall strength of the axle
  6. Torque the axle to the bike manufacturers recommendation (mine was 6 Nm)

Cost savings[edit]

  1. Total cost $0.375
  2. Commercial Equivalent - $32.10 [2]
  3. $31+ or 98.8% savings

Benefited Internet Communities[edit]

  1. Transport
  2. Sustainability
  3. Green Living