Photos: EADS Airbike, the bike that's grown not made

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Say hello to the custom bike that started out as just so much nylon powder...

This is Airbike, a bicycle whose space-age looks are the least interesting thing about it...

The Airbike is the work of aerospace and defence company EADS, which used a manufacturing process that involves growing parts from high-strength nylon powder. The technique is called additive-layer manufacturing (ALM) and is similar to 3D printing.

The bike started life as a fine nylon powder, but EADS said carbon-reinforced plastics or fine metal powder such as titanium, stainless steel or aluminium can also be used. The bike's design was honed using computer-aided design and the construction itself involved a powerful laser-sintering process in which successive, thin layers of the nylon powder were added until the solid, fully formed bike emerged.

Published: March 10, 2011 -- 11:45 GMT (03:45 PST)
Photo by: EADS

Caption by: Natasha Lomas
Here's a close-up of the seat. The bike is a custom design, made to measure for one rider - doing away with the need for adjustable parts, said EADS.

While not the most comfortable-looking saddle, it features an auxetic design - meaning it can flex to provide some cushioning, according to the company.

Published: March 10, 2011 -- 11:45 GMT (03:45 PST)
Photo by: EADS

Caption by: Natasha Lomas
Here's a close-up of the bike frame. The front section of the frame features an integrated truss structure which EADS said is designed to reduce the bike's weight without compromising its rigidity.

The ALM process allows complete sections of the bike to be built as one piece. The wheels, bearings and axle are all incorporated into the 'growing' process, meaning they are built at the same time. EADS said parts and products produced by ALM are up to 65 per cent lighter than traditional, machined parts but just as strong. The ALM process also uses about one-tenth of the material required in traditional manufacturing and reduces waste, according to the company.

Weight reduction in components and vehicles constructed using ALM processes could lead to considerable savings on fuel and a reduction in carbon emissions, the company added.

Published: March 10, 2011 -- 11:45 GMT (03:45 PST)
Photo by: EADS

Caption by: Natasha Lomas
Here's a close-up of the rear wheel and its Kevlar belt, which replaces the traditional bike chain - so there's no need to mess around with bike oil.

While the Airbike is only a proof of concept for the ALM technology, EADS believes the technique has the potential to revolutionise design and manufacturing, and significantly reduce costs.

"Complex designs do not cost any extra to produce. The laser can draw any shape you like," noted Andy Hawkins, lead engineer for ALM at EADS, in a statement.

Over the long term, EADS believes ALM techniques could do away with the need for production lines and factories entirely. In the short term, it said the technology is likely to be used in industrial applications such as aerospace, the motor industry and engineering.

Published: March 10, 2011 -- 11:45 GMT (03:45 PST)
Photo by: EADS

Caption by: Natasha Lomas