Firefly Revives Rim Brakes with 3D-Printed Titanium Frame and 40mm Tire Clearance

Key points

• The new Firefly bike is designed to clear 40mm tires, a significant upgrade from traditional 23mm rim brake setups, requiring a custom titanium all-road fork with a 3D-printed crown.
• The braking system uses a custom cable-pull variation of the Cane Creek eeBrakes, originally designed for Brompton bikes, to fit the larger tire and wheel package.
• The frame utilizes 3D-printed chainstay yokes, seat tube knuckles, and wishbone seat stays to accommodate wide tires while maintaining drivetrain compatibility and aesthetic symmetry.
• Wheel attachment uses a new 3D-printed through-bolt dropout system with custom brass fittings, which is lighter and stiffer than traditional plate dropouts or quick releases.
• The bike is compatible with modern drivetrains, including Shimano Di2, Campagnolo mechanical, and SRAM AXS via Growtac Control brake levers, and is priced at $7,200 for the frame and fork, with complete builds ranging from $10,000 to $14,000.

Background

Firefly Bicycles has a history of integrating 3D-printed titanium components into their bikes, including recent releases of 3D-printed titanium radar mounts for seat collars in August 2026. This new rim brake model continues their focus on combining traditional cycling elements with advanced manufacturing techniques.

Why it matters

This release challenges the industry-wide shift to disc brakes by demonstrating that rim brakes can be modernized with 3D-printed titanium components and modern drivetrain compatibility, offering riders an alternative that combines the simplicity of rim brakes with the performance and clearance of contemporary all-road bikes.

What to watch

Firefly is currently selling the frame and fork for $7,200, with complete custom bikes available in the $10,000 to $14,000 range. Riders interested in the build can visit the Firefly website for more information and to place orders.