Redefining Lightweight: Passoni's 1.4kg Titanium Frame

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February 27, 2026 Applications 9630

Passoni’s new Omni OT-01 bike combines 3D printed and machined titanium

Passoni has launched its new Omni OT-01 bicycle, featuring a frame that innovatively integrates CNC-machined and 3D-printed titanium components. This showcases the mature application of additive manufacturing in the high-performance cycling sector.

This titanium frame weighs only 1.4 kilograms, which is 120 grams lighter than the brand's previous road bike frame, achieving the design goals of being "lighter, stiffer, and cleaner." Its manufacturing strategy selects the optimal process based on component function: the head tube, which directly affects steering precision and rigidity, is CNC-machined from Grade 5 titanium billets in three sections. Conversely, the dropouts, which secure the wheel axles, are produced using metal 3D printing technology. This enables an innovative fully enclosed design, resulting in smoother lines and a more balanced frame silhouette.

Passoni has been utilizing 3D printing technology since 2018, consistently adhering to the philosophy that "technology serves function." Brand owner Matteo Cassina emphasizes: "We don't pursue technical gimmickry; every component must be practical and perfectly integrated." Through collaboration with local partners, the brand employs 3D printing to manufacture complex structural parts that are difficult to achieve with traditional methods, while also significantly reducing waste of the expensive titanium material.

The new frame is available for custom order at the Milan studio, starting at €8,560. This product exemplifies the trend in high-end bicycle manufacturing: ensuring core structural strength through CNC machining, combined with achieving lightweight design and design freedom through 3D printing. The synergy of these two technologies is creating a new generation of high-performance bicycles.