The EVO utility bike by Huge Design, Forty One Thirty Cycle Works and PCH Lime Lab. Photo by Gauthier Richard.The project merged an old-world, bike-building craft with new technology and a modern design process,” explains Chris Harsacky, founder of Huge Design and lead designer on the team. Together, they began developing an urban utility bike called EVO that would allow riders to very easily attach and detach different components — baskets, racks, pannier bags, a child seat — to the front and rear of the frame depending on their activity. To achieve the plug-and-play effect, the team designed a bike frame that combined off-the-shelf 4130 chromoly steel tubing with 17-4 PH stainless steel metal lugs that were integrated into the frame. Due to the complex geometry of the lug design, which included a unique interior mechanism for clipping accessories in and out, engineers at PCH Lime Lab had the lugs build through Proto Labs’ additive manufacturing (3D printing) process of direct metal laser sintering(DMLS).Read the full case study on Huge Design’s development of its EVO utility bike.