3D-Printed Bicycle Drivetrain Shows What Happens When You Have Gears Without a Chain

Sergii Gordieiev, the engineer behind “The Q,” is the mastermind behind some incredibly unique innovations, such as transforming regular bicycles into something entirely different. His new project involves disassembling a basic bike, removing the chain and derailleur, and replacing them with a chain composed of 3D printed gears. The end result is a stripped-down single-speeder that delivers power directly from the crank to the wheel, with no sign of chain slap or rattling worn chains.

Gordieev starts with a conventional bike, removes the chain, derailleur, and everything else, and then installs a one-of-a-kind spur gear combination created with Fusion 360. The drivetrain consists of a large gear that connects to the crank arms (where the chainring would normally be), as well as a series of smaller idler gears that fill the gap between the crank arms and the back wheel. Others have used three 16-tooth idler gears, but Gordieiev has opted for a series arrangement, which is simpler and more reliable.

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All of these components, as well as the mounts and supports that keep them firmly in place even when things go hairy, were created using the same 3D printer: a Phrozen ARCO. The epoxy used for these parts is of high quality, so they’re far more likely to last, which is useful because they can withstand the full force of your cycling without squeaking.

Gordieiev to go through a significant amount of trial and error to get the proper gear balance that will just function, smoothly, silently, and without the irritating slippage or backlash that comes with a regular chain. Getting everything to fit together in the first place is a real conundrum, because each gear must fit snuggly into an axle or bearing fastened to the frame, or the entire drivetrain will fly apart the moment you start pedaling.

When the bike is up and running, it is evident that the entire concept works in the real world. Sure, the moving teeth are a little louder than a quiet-shifting chain, but they move smoothly and consistently. While the power transfer is silky smooth, with almost no play from a worn chain, it’s a single-speed design, so you’re trapped heading downhill at full speed.
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