Fuller Moto, the Atlanta, Georgia based custom vehicle shop, used 3D printing to develop the 2029 Majestic motorcycle, based on the ahead of its time French designed 1929 Majestic motorcycle.
The original motorcycle is a favorite of Bobby Haas, a Dallas-based collector. He gave the shop the go-ahead to work on building the futuristic motorcycle. “We know we’re doing something that has never been done before. There is no actual blueprint, we’re not doing a production cycle, we’re doing a piece of work that is a rolling art. It is unique,” Haas explains.
Early on in the project, Fuller Moto brought Nick Pugh onboard. The transportation designer has worked on Star Wars movies and the X-Men series. Pugh took the shop’s pencil sketches of the 2029 Majestic and turned them into 3D models.
The next step was for the team to begin building the motorcycle. Bryan Fuller, founder of the shop, explains that the team began with the original frame of an electric motorcycle from California-based company Zero Motorcycle.
Onto this, they wanted to build the 2029 Majestic using metal 3D printed parts. However, as Fuller explains, Fuller Moto is an “old-school” hot ride shop, so they also used “old-world” technology, such as welding, hammering, and shaping.
Blending Modern and Old-World Technologies
The result is an electric bike with a body on top of it instead of just a frame and a tank. It also boasts hub-centric steering and plexiglass wheels to complete the futuristic look.
The design was extremely complex and encompasses multiple organic shapes which would be impossible to create using traditional manufacturing methods.
With multiple pieces which fold in and out of themselves, sending the CAD files to be 3D printed in titanium by Oerlikon AM was the best option.
“I think the 3D printing aspect, it’s something you’ve got to really wrap your brain around to figure out that you can do all these different things, it opens up a lot of possibilities for what you can create,” explains Bryan Heidt, the lead metal fabricator at Fuller Moto, adding: “The metal printing has been what’s really changed things because before we could only do plastic stuff and it would be brittle and fragile but the new pieces we’ve been getting, they’re rock solid.”
These innovative build techniques have resulted in an unconventional yet extremely cool motorcycle. The Fuller Moto 2029 will be on display at the Haas Moto Museum & Sculpture Gallery. Check out more from behind the scenes in the video below.
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