Metal 3D printing helps revive century-old motorcycles

Competition Distributing LLC, a Pennsylvania-based manufacturer of vintage Harley-Davidson and Indian motorcycle parts, is using metal 3D printing technology to reproduce rare parts that are a century old and difficult to obtain through traditional means. The company focuses on motorcycles before the 1930s and provides original and precision aftermarket parts to collectors, museums and restorers around the world. To meet growing demand and overcome the scarcity of key parts, with the support of industrial 3D printer supplier Farsoon Technologies, it adopted laser powder bed fusion (LPBF) technology to introduce metal additive manufacturing into the internal production process.

"Some of these motorcycles are over 100 years old and are too valuable to be ridden on the road, even if the museum allows it," said Sean Jackson, head of operations. Faced with the problem of running out of original casting inventory, Jackson and co-founder Kevin began scanning the parts and reproducing them using Farsoon's FS200M-2 dual-laser metal 3D printing system. This system is designed for medium-scale production. "These parts are not just for museum exhibits, we want to make them available to ordinary enthusiasts so that they can build, ride and experience early motorcycles just like 100 years ago."

Competition Distributing had experience with polymer-based additive manufacturing, but their metal 3D printing business was outsourced before. According to Jackson, laser powder bed fusion technology is significantly faster and more flexible than traditional mold making and casting methods, which may take months. This operational advantage prompted them to decide to bring metal printing business into the company.

The FS200M system was installed and put into operation in October 2024, and has been running almost continuously. Jackson called the move a turning point for the company. "With it, we can now deliver high-quality end-use parts in just days instead of months. Most importantly, our customers are very happy with the results." In particular, the system is capable of producing rare frame parts and cast elements that are difficult to source or replicate. One example is a cylinder head based on a 1928 Rudge Cycle Co. design, which was 3D printed in AlSi10Mg aluminum alloy. Another project, "The Pennsylvania 8", incorporated 3D printed parts into a completely restored motorcycle.

Jackson explained that the company primarily prints structural parts using 316 stainless steel, but is also preparing to expand into aluminum alloys, 17-4 stainless steel and titanium alloys. These material options will support a wider range of repair needs, especially for load-bearing or high-performance parts.

Adopting this technology required a learning process. “It took us about three to four weeks of consistent printing to really optimize our process,” Jackson said. Unlike geometries optimized for additive manufacturing, many of the scanned vintage parts lacked symmetry or internal support structures. Adapting support structures and print settings for these irregular geometries required fine tuning.

The support of Farsoon’s technical team was crucial to the successful integration of this technology. “Our team consists of engineers and mechanics, so the communication with Farsoon’s technical team was very efficient.”

Farsoon’s monitoring tools support remote access and job management. “I can remotely monitor and control the printing process through my phone, adjust powder settings, and even remove individual parts without canceling the entire job.” This feature reduces material waste and increases operational flexibility.

A vintage motorcycle restored with 3D printed parts was unveiled at Farsoon’s booth at the Rapid + TCT show in Detroit in 2025. The Competition Distributing team was also at the show to answer questions and discuss the role of additive manufacturing in recreating engineering designs from a century ago.