The combination of different manufacturing processes is what drives the process development team of tübingen stahlfeinguss tsf . The project team already started in 2019 to give shape to an extraordinary customer requirement. The goal was a weight-reduced and cost-optimized version of an existing welded construction of a “fun bike”. The interdisciplinary tsf-team took care of the matter and designed a dimensionally stable, visually appealing frame in close partnership with the customer. At the same time, a manufacturing process was developed that meets the requirements: low costs despite the low number of individual pieces, mapping of the topology-optimized, bionic shape and maximum workpiece stability. The separate challenge for process development was to optimize the cost-intensive technology of SLM (selective laser melting). “Our gears fit together perfectly,” says Dr. Stüber, Head of Technology and Quality after developing a process from a 3D printed model in combination with the advantages of the conventional investment casting process. With a project lead time of 25 days, tsf lived up to its reputation as the fastest investment casting company in Europe and once again gave the idea a shape.