Designer & maker Asheville, North Carolina
I design parts and make them.
I'm Dylan Banera. I work in CAD, 3D printing from FDM to metal LPBF, and CNC and manual machining, mostly on bikes: frames, pedals and stems.
- Intern
- Industry NineAsheville, NC · 8 months from October 2026
- 3D printing technician
- Peak TechnologyAdditive manufacturing unit · June to October 2026
- Founder
- TBD Bikes3D-printed bike frames · since March 2025
- Student
- De Anza CollegeDesign and Manufacturing Technologies
Featured · Aug 2025Dirt Jumper V2: 3D printed in aluminumMe with the finished bike. Photo: Wolf Tooth
Work
-
GST-279 full-suspension frame
My full-suspension frame design for TBD Bikes: SLS PA12 prototype lugs on carbon tubes, from the Fusion 360 model to the bonding jig and both triangles. , 1 video -
Dirt Jumper V2: 3D printed in aluminum
A rideable dirt-jump frame printed almost entirely in aluminum (metal LPBF), with generative-design junctions and lattice tubes. , 2 videos -
Dirt Jumper V2: machined junctions
The same V2 frame on carbon tubes, with 7075 aluminum junctions machined 5-axis from my CAM. Industry Nine showed it, unfinished, at Crankworx Whistler 2025. , 8 videos -
Bike Pedals
A bike pedal I keep redesigning: resin prints at home, then PA12 bodies printed at De Anza on 1020 steel spindles I turned. The current revision is V4, "The Reboot." , 4 videos -
Dirt Jumper V1: 12 days to Sea Otter 2025
A dirt-jump frame with SLS-printed Nylon 12 lugs bonded to carbon tubes, designed and built in 12 days for Sea Otter Classic 2025. , 3 videos -
Printed triple clamps
Upper and lower triple clamps I designed in Fusion 360 for a dual-crown fork: FDM prints, assembled on the fork. , 2 videos -
AMD event display stands, printed in batches
A display stand I designed in Fusion 360 for AMD summit cards, made by the dozen: FDM printed at first, then SLS in Nylon 12. -
Dirt bike rear suspension linkage
A dirt bike rear linkage I designed in Fusion 360 inside a full-bike assembly: FDM-printed parts, bolted on the bike. , 3 videos -
Printed terrain relief maps
Multi-colour FDM-printed terrain relief maps with the route raised in red, plus a La Quinta 70.3 plaque. -
Dirt bike peg and button covers
A footpeg cover and handlebar button covers I designed in Fusion 360 for KADE 177's dirt bike, printed and fitted on the bike. -
Lever depressors and chain tension gauges
3D-printed brake and clutch lever depressors and chain tension gauges for motorbikes, with my TBD Bikes logo. -
Printed products: a camera mount, containers and cup holders
A sun-visor camera mount, knurled screw-top containers and hex-pattern cup holders that join up, all designed in Fusion 360 and FDM printed. -
Lathe work
Turning a part on a manual lathe and checking its diameter with a micrometer. -
Top-load BMX stem designs
Printed prototypes of my top-load BMX stems, the V1 design in CAD, a lattice version exported for printing, and the basic top-load stem from my TBD Bikes parts set. , 2 videos -
MTB stems for TBD Bikes
Two MTB stems I designed in Fusion 360 for TBD Bikes in spring 2025: CAD for both, and printed parts of the trapezoid-body stem. , 2 videos -
Printed MTB/gravel stem: generative design
An MTB/gravel stem shaped by generative design in Fusion 360 and printed in Nylon 12 on an HP 580, with heat-set inserts for the bolts. , 1 video -
CNC plates, programmed by hand
6061 aluminum plates, a smiley face among them, that I CNC-milled from G-code I wrote by hand with subprograms and L repeats. , 2 videos -
Crank arms and a 3-piece crankset
Crank arms I printed, some in resin and some in powder, with different pocket patterns, a printed chainring and guard, and a 3-piece crankset I designed in Fusion 360 for TBD Bikes. -
Laser engraving on wood
Images from the web engraved into wood on my own Longer laser, run from LaserGRBL, including a dragon, tiles and a coaster. -
3D-printed putter head
A mallet putter head I designed in Fusion 360 and FDM printed. -
Finishing large printed robot panels
Large printed robot panels I filled and sanded myself at Peak Technology, where I was a 3D printing technician. -
Frame lug prototypes
Printed lug, junction and tube-section prototypes, mostly for my Dirt Jumper V1, Dirt Jumper V2 and GST-279 frames. -
Other prints
Smaller 3D prints: piston models, moving mechanisms, a clearance test and a printed bolt, plus a 3D scan. , 2 videos
About
My journey into 3D printing, CNC and CAD began at age 10, when I unwrapped my first 3D printer, a Monoprice Select Mini, on Christmas morning. It was a gift I'd convinced my dad to get me after watching countless YouTube videos.
What started with printing small trinkets grew into a passion for design and manufacturing, taking me from basic designs in Tinkercad and SketchUp to mastering Fusion 360, and now exploring Creo, SolidWorks, nTopology and various CAM software. Over the years I've upgraded from that first printer to a number of FDM printers, and in the past two years I've invested in my own: an Anycubic M7 Pro resin printer and a Prusa MK3S+.
Today I run TBD Bikes, where I design 3D-printed bike frames, and in October 2026 I started an 8-month internship at Industry Nine in Asheville, North Carolina.
I hope this portfolio shows my growth, creativity and drive to push the boundaries of digital fabrication and manufacturing.
Experience
- Industry NineAsheville, NCintern (October 2026 to present). An 8-month internship with the U.S. maker of machined bike hubs, wheels and components.
- Peak TechnologySan Jose, CA3D printing technician, additive manufacturing unit (June to October 2026). Ran and maintained an SLA, SLS and FDM print fleet for OEM customer jobs, built a cost model for quoting across all three processes, and wrote the unit's capabilities guide, DFAM references and print-setup procedures.
- TBD BikesSan Jose, CAfounder and frame designer (March 2025 to present). Designed a rideable dirt-jump frame 3D printed almost entirely in aluminum, shown at MADE Bike Show 2025 and Sea Otter Classic 2026. Built the V1 frame, Nylon 12 lugs bonded to carbon tubes, in 12 days for Sea Otter 2025; the build was featured in Pinkbike, Bikerumor and All3DP.
Skills
- 3D printing: FDM, SLA, SLS and metal powder bed fusion (LPBF), binder jetting; design for additive manufacturing (DFAM)
- Metal AM: generative design and TPMS/gyroid lattices for aluminum LPBF, polymer proof prints before metal builds, hybrid AM and CNC machining
- CAD/CAM: Fusion 360 (parametric, surface and generative), Creo, SolidWorks, nTop and Mastercam; GD&T
- CNC machining: setup, CAM toolpaths, edge-finding, work and tool offsets, G-code hand programming
- Manual machining: milling, turning and blueprint reading
- Laser etching; Klipper firmware
Hobbies
- Bike riding and bike maintenance
- Motorsport, motocross and go-karting
- Car maintenance
- Machining, 3D printing and designing
Machines I've run
- 3D printers: Formlabs (Form 4, Form 3/3B, Fuse 1 and Fuse 1+ 30W), Stratasys, HP, Bambu Lab, Prusa, Anycubic, Elegoo, Gcreate, Creality, Ultimaker, Monoprice
- Machine tools: Haas, Kitamura and Bridgeport
Education
De Anza CollegeSan Jose, CADesign and Manufacturing Technologies (July 2024 to present). Completed Manual Machining, CNC Setup and GD&T; President of the 3D Printing Club.