Unveiled at Rapid 2015 in Long Beach, California, TE Connectivity's exercise in 3D printing demonstrates the ability to design a motorcycle on a computer, print it in plastic, add tires and a motor, then take it for a spin. In fact it may take a little more than that to actually end up with a complete functioning motorcycle; nonetheless, the concept is nothing short of exciting...

...Modeled in a Harley-Davidson Softail fashion, the motorcycle measures around 8 ft (2.4 m) long, weighs 250 lb (113.4 kg) and consists of more components than its designers can account for. Its frame, printed after a process of trial and error, can support a total of 400 lb (181 kg) – that would be two adult passengers. Apart from the small electric motor and tires, some other outsourced parts include the braking system, electrical wiring, battery, belt drive, mirrors, sidestand and some bolts.

The highlight is, of course, its fully functioning status. A small 1 hp (750W) electric motor can power a 15 mph (24 km/h) ride for several minutes. Though this may not sound ground-breaking, it doesn't necessarily need a bigger battery or a stronger engine to make a point as a showbike at a conference on printing, scanning and additive manufacturing. All that matters is that, after some 1,000 work hours and US$25,000, TE Connectivity has come up with a proper motorcycle indeed.

The main load-bearing parts were constructed with Fused Deposition Modeling (FDM) technology, the process of injecting layer upon layer of ABS (acrylonitrile butadiene styrene) plastic enriched with the heat resistant resin Ultem 9085. With this process, TE printed several parts with complex dynamic properties, such as the frame.