Dylan Banera

WorkBike Projects

Sheet 04 of 23

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."

Date
Jun 2025
Media
15 photos · 4 videos
CAD
Fusion 360
Bodies
Resin, printed at home; PA12 on a Formlabs Fuse 1 (SLS) and an HP 580 (MJF) at De Anza
Machined spindles
1020 steel, turned by hand on a manual lathe
Disciplines
BikesPedals3D PrintingManual MachiningCAD
Fig. 01V4 on the bike: the grey body, SLS PA12 printed on the Fuse 1 at De Anza, on a steel spindle I machinedEnlarge

Notes

V2 (2024) was a bearing-less platform pedal I printed in Anycubic Ultra Tough black resin on an Anycubic Photon S at home. The clip follows one print from the printer through an ultrasonic wash and onto the bike.

V4, "The Reboot" (2025), started as a prototype with a Nylon 12 body and spindle printed on the HP 580 at De Anza, and small parts in TPU 95A printed on a Bambu Lab X1E. Its tolerances still needed tightening a bit. For the set of parts I designed for TBD Bikes in spring 2025, I set V4 up for SLS PA12 with 4130, 4140 or 17-4 steel spindle options. The rest of that set is on the MTB stem, BMX stem and crank arm pages.

Apart from that early prototype's printed spindle, the V4 bodies ran steel spindles I machined by hand: I turned them from 1020 mild steel on a Leblond manual lathe. The test pedals (June 2025) had Nylon 12 (PA12) platforms printed at De Anza, the grey one on a Formlabs Fuse 1 (SLS) and the white one on an HP 580 Color (MJF), with small parts I printed in Polymaker TPU 95A on a Bambu Lab P1S. My verdict after a trail ride: a little less grip, but not too bad.

Along the way I made FDM test prints of the V2 body and modelled V2.2 in Fusion. For V4.1 I drew the machined spindle (9/16-20 UN-2A thread) in January 2025. I went through several rounds of prototype bodies in black, orange, grey and clear, most of them printed in various resins at home. The resin bodies broke on different kinds of jumps.

Photos and videos

18 figures

Fig. 02V2 (2024): bearing-less, printed in black resin
Fig. 03V2 end view on the crank
Video 0:37
Fig. 04Printing V2 at home: the black resin print off the Anycubic, an ultrasonic wash, then fitting the pedal on a BMX crank
Fig. 05Three FDM test prints of the V2 body, supports still on
Fig. 06An FDM test print fitted on a crank
Fig. 07The V2.2 body in Fusion, from the file "Pedal V2.2 - printed - Bushing test"
Video 0:20
Fig. 08V4 in CAD: the body, spindle and small parts
Fig. 09Pedal V4 set up for SLS PA12 with steel spindle options, for the TBD Bikes set
Fig. 10Early V4 prototype from the HP 580: Nylon 12 body and spindle, with TPU parts
Fig. 11The early V4 prototype assembled: HP 580 Nylon 12 body and spindle
Fig. 12Every V4 part laid out: body, spindle, bearings and the small parts, with a printed stem and faceplate at the top
Video 0:29
Fig. 13V4.1 in Fusion: a section view of the spindle and its bearings, then my drawing of the machined spindle
Video 0:50
Fig. 14May 2025 update: lathe and mill work, a section view of the 1020 steel spindles I machined, and a printed pedal on a steel spindle
Fig. 15A clear resin body with its threaded spindle fitted
Fig. 16Bodies from several rounds of prototypes, mostly resin prints from home, with spindles and sleeves. Several of the resin ones broke on jumps
Fig. 17A black resin body that cracked through the centre bar on a jump
Fig. 18A blue-grey body cracked beside the spindle housing
Fig. 19An orange body with one end broken off