Generative Design is an iterative design process that uses software to optimise a volume according to given constraints.
At VAN RYSEL, this process has allowed us to explore and then produce a bespoke fork, locally.
Following the PNPL 3.0 work carried out in collaboration with Autodesk, our VAN RYSEL and Tech'Off* engineers have, for the first time, allowed us to ride a bike in real conditions with a fork resulting from Generative Design.
*DECATHLON's internal network of skills and know-how in mechanical engineering. Laboratory, 3D simulation and design, eco-design.
Generative Design responds through an optimisation process to a series of personalised constraints. Thus, depending on personal preferences, the behaviour of the fork can be different from the most rigid to the most comfortable.
Generative Design allows for higher levels of comfort while maintaining responsiveness in curves.
For the moment, only a few 3D printers can accept this type of volume with a minimum printing constraint of 1.2mm. As a result, printing can be carried out as close as possible to the user. And this in just 15 weeks from writing the specifications to final delivery of the product.
3D printing technologies are evolving rapidly and our internal teams (Addlab) allow us to keep a close eye on and explore the use of Generative Design from the saddle rail to the bicycle frame.
We wanted to go beyond the PNPL 3.0 concept bike and explore this technology in practice. We chose to design a series of first forks and then test their properties in our laboratories. We chose titanium because it is the printable metal with the best weight/stiffness ratio, with the least amount of alloy possible.
The results, more than satisfactory, allowed us to run one of them on our traditional "Tour du Midi "*.
*The Tour du Midi is the internal name given to the route taken by our internal teams. It even has its own Strava segment.
The aim is not to commercialise this technology, but rather to learn from it for our future designs. Further iterations will be carried out to optimise the mass gain.
Like any new technology, this process is currently expensive and not available to everyone. A 3D printed fork from Generative Design is 20 times more expensive than a conventional fork. However, we want to democratize this technology and are exploring it.
At VAN RYSEL, innovation is at the heart of our priorities.
Like this project, we are constantly looking for new partners to carry out our future exploration projects. The sustainable and ecological dimension is also at the heart of our thinking. With the help of Generative Design and 3D printing, we wish to propose an alternative to carbon, while ensuring its qualities.
© 2026 VAN RYSEL
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