Behind the Scenes: How We Engineer and Manufacture for the Wild

When you are out on the trails or twisting the throttle on the track, the last thing you should be thinking about is whether your gear can handle the stress. You should just be enjoying the ride.

Behind every piece of Ride Adapt gear is a rigorous process of material selection and manufacturing strategy. Our co-founder, Dom, brings a deep background in product design and manufacturing, with a specialised focus on custom and low-volume medical devices.

In the medical sector, there is zero room for error. We’ve brought that exact same obsessive engineering mindset to the adaptive sports world. The challenge? Creating components that are tough enough to survive brutal outdoor environments (think mud, sweat, rain, and relentless vibration), while keeping production affordable for relatively small, custom batches.

To pull this off, we don’t rely on just one assembly line. We use a curated mix of cutting-edge global supply chains and advanced manufacturing technologies.

Here is a look inside our toolkit.

Additive Manufacturing (Beyond "3D Printing")

Dom has been working with 3D printers since 2003, back when the technology was mostly used for rough visual models or reserved for rich industries. Today, the tech has completely matured. We use industrial Additive Manufacturing (AM) to create highly functional, end-use components that go right onto your bike or motorcycle.

Here are the processes we swear by:

1. HP Multijet Fusion (MJF) — Industrial Nylon 12

For parts that need to be incredibly tough but lightweight, MJF is our go-to. It uses a fine powder to build solid, ultra-precise parts out of PA 12 Nylon.

• The Benefits: It is naturally hydrophobic (repels water), completely solid throughout, and handles outdoor environments beautifully.

• The Magic Touch: We put these parts through a vapour smoothing process. This doesn't just give them a sleek, premium, low-friction finish—it actually increases the material's toughness. This is critical for components like our arm trays, which need to dynamically bend and flex to offer comfort without breaking.

• Smart Engineering: Because the material is so stable, we can melt brass threaded inserts directly into it for secure bolting, and even design complex internal channels right into the structure.

  
  

HP Multijet Fusion components for the Ride Release. We're able to design extremely complex geometry and produce in a tough material with a low friction finish.

2. High-Performance TPUs (Flexible & Shock-Absorbing)

For components that interact directly with your body or require flexibility, we use specialised extrusion processes to print with TPU (Thermoplastic Polyurethane).

• Soft Toppers: We use a unique foaming TPU that acts as a compliant, shock-absorbing cushion. It takes some serious fine-tuning to print correctly, but the comfort is worth it.

• Straps: Our structural straps are fabricated in a denser TPU that is remarkably tear-resistant, flexible, and immune to weathering.

  
  

3. Metal Additive Manufacturing (316L Stainless Steel)

Some components—like our quick-release mechanisms, studs, and prongs—face massive mechanical stress. For these, plastic isn't enough. We use industrial metal 3D printing to grow these intricate shapes out of 316L Stainless Steel.

• This gives us the geometric freedom to design incredibly complex, interlocking mechanisms that would be impossible to make with traditional tools.

• The result is a part that is super tough, extremely corrosion-resistant, and polished to a finish that shrugs off the elements without needing any artificial coatings.

316L stainless steel component for the Ride Release. We use MJF inserts to reduce friction.

CNC Machining: Old-School Precision for High-Stress Loads

While 3D printing gives us incredible geometric freedom, CNC (Computer Numerically Controlled) Machining is where we turn for absolute, microscopic precision. CNC involves taking a solid block of high-grade metal and using computer-guided cutting tools to carve out the final part with incredibly tight tolerances.

We choose our CNC metals based on the physics of the ride:

• 7075-T6 Aluminium Alloy: When a component needs to be incredibly stiff and strong but light enough that it won't weigh you down, we use 7075-T6. This is an aerospace-grade alloy with a strength-to-weight ratio that rivals steel, making it perfect for structural, load-bearing parts.

• Heavy-Duty Stainless Steels: When a component is subjected to relentless, repetitive friction—like a bushing surface where parts pivot and rotate—or where extreme fatigue resistance is required, we carve it from solid stainless steel to ensure it lasts a lifetime.

The B-Adapt. CNC machined aluminium alloy, anodized black.

The Ride Adapt Promise: 

We don’t believe in a "one-size-fits-all" manufacturing method. By matching the exact right material to the exact job it needs to do, we build adaptive gear you can trust.