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3D printing breathes new life into 100-tear-old motorcycles

by Daniel Rhodes
April 26, 2025
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3D printing breathes new life into 100-tear-old motorcycles
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Keeping vintage motorcycles running is a true labour of love. While there’s nothing quite like hearing an old V-twin engine roar back to life or feeling the raw shift of a manual gearbox, restoring these machines is often a race against time — and scarcity.

Restorations of pre-war Harley-Davidsons and Indians often hit a wall: original parts are either incredibly rare or too fragile to reuse. Even after scouring swap meets and online auctions, many restorers find themselves stuck, waiting endlessly for a part that may never appear.

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That’s where modern technology is stepping up to help.

Despite some traditionalists’ scepticism, metal 3D printing has become an essential tool for saving vintage motorcycles from extinction. At the forefront of this movement is Competition Distributing LLC, a Pennsylvania-based company committed to keeping the spirit of early motorcycling alive.

Their goal is not merely to produce static showpieces, but fully functional machines ready for the open road. To achieve this, they have embraced cutting-edge equipment from Farsoon Technologies, using the dual-laser FS200M-2 metal 3D printer to meticulously recreate components from over a century ago.

“We’re dealing with parts that simply haven’t been made for 80 to 100 years,” explains Sean Jackson, Head of Operations. “If they’re gone, the only option is to build them ourselves.”

Before installing their own Laser Powder Bed Fusion (LPBF) system in late 2024, Competition Distributing experimented with polymer 3D printing and outsourced metalwork, but found traditional casting methods too slow and imprecise. Since adopting in-house metal printing, they’ve cut production times from months to mere days.

One standout project is the reproduction of a 1928 Rudge Cycle Co. cylinder head, printed in lightweight, durable AlSi10Mg aluminium alloy. Another highlight is “The Pennsylvania 8,” a fully restored motorcycle showcasing several discreet 3D-printed parts alongside original elements.

Working mainly with 316 stainless steel, the company has recently expanded into aluminium, 17-4 stainless steel, and titanium, allowing them to craft everything from structural frames to heavy-load components.

Recreating century-old designs hasn’t been without challenges. The asymmetrical, hand-crafted nature of early engineering required extensive testing and fine-tuning. With support from Farsoon’s technical team and remote monitoring tools, Competition Distributing has managed to master this delicate balance between heritage and innovation.

While purists may debate the authenticity of using 3D-printed parts, for many vintage motorcycle enthusiasts, keeping these legends alive — and on the road — is what truly matters.

For those seeking rare parts or curious about how modern tech is reviving historic machines, Competition Distributing’s catalogue is well worth exploring — it might just be the key to getting your own classic rolling again.

Source: Rideapart

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