Precision and passion for a high performance downhill bike
CNC Future Technics GmbH | Finne, Germany
Key Takeaway
With the Fracebike, CNC Future Technics GmbH has brought a visionary project to life. This high-end fully CNC machined downhill bike made from high strength aluminum was made possible through the use of the hyperMILL® CAD/CAM solution. Applying 5-axis machining to achieve maximum precision and perfect surface quality, from the first prototype to the planned small series production run, the Fracebike delivers outstanding quality, stability, and performance. It has also proven successful in international racing.
“There are no limits for us anymore. Whether 2D, 3D, or full 5 axis simultaneous machining, hyperMILL® always provides the right, safe solutions.”
Bernd Iwanow, Managing Director, CNC Future Technics GmbH
Bernd Iwanow, Managing Director of CNC Future Technics GmbH, fulfilled a personal dream when manufacturing a fully CNC milled downhill race bike from high strength aluminum that epitomizes the highest standards in design, materials, and machining. The hyperMILL® CAM solution from OPEN MIND Technologies AG plays a key role, especially for demanding 5-axis machining and simulation driven manufacturing processes.
Bernd Iwanow fulfilled a dream with the Fracebike. A high-end downhill bike built for maximum riding performance.
The Fracebike is no ordinary downhill bike. It is the result of engineering expertise, precision, and a deep passion for cycling, fully milled from premium aerospace grade aluminum. Its name says it all, ‘Fracebike’ blends ‘Fräsen’ (milling) and ‘Racebike’ and captures the idea perfectly. The goal was a bike that meets the highest requirements for quality, stability, and performance. Iwanow, founder of CNC Future Technics, had the vision to develop his own high end bike and founded a second company, CNC Bike GmbH, for this purpose. He spent more than a year on design and development before the first prototype was produced. Numerous optimizations followed, along with additional prototypes, eventually resulting in a thoughtfully engineered overall concept, a downhill bike built for maximum riding performance that also proves itself in professional use.
High end CAM for a performance bike
“Our previous CAM system reached its limits, especially in 5-axis machining and simulation. It simply could not meet the increasing demands,” Iwanow explains. During the search for a new software solution, he connected with the OPEN MIND reseller N+P Informationssysteme GmbH in Meerane (Germany). “I already knew hyperMILL® from before I became self-employed, and I was impressed by the reliability of its 5-axis simultaneous machining. Since that time, the software has advanced significantly and hyperMILL® is now far more powerful.” The decision was clear and since 2023 CNC Future Technics has relied on hyperMILL®. One year after implementation, Iwanow programmed and manufactured the main frame and rear triangle of the first Fracebike with hyperMILL®.
Programmed and manufactured with hyperMILL®, the Fracebike main frame made from high strength aluminum clamped in the machine.
hyperMILL® not only enables precise 5-axis machining of complex components. It also helps CNC Future Technics make full use of its Hermle machining centers. To achieve perfect surface finishes, the software provides specialized strategies for high precision machining, essential for visible components on a high-end bike. Features like High Precision Surface Mode, which generates toolpaths directly on the CAD model surfaces, create exceptionally smooth finishes. Smooth Overlap also ensures flawless transitions between machining areas. “There are no limits for us anymore. Whether 2D, 3D, or 5-axis simultaneous machining, hyperMILL® always provides the right and safe solutions,” says Iwanow.
The frame in hyperMILL® with finishing toolpaths for the top and down tubes.
hyperMILL® VIRTUAL Machining Center, material removal simulation of the milling process.
Particularly for prototypes, he emphasizes, error free machining is critical. “Every step must be perfect. The first part needs to fit.” With hyperMILL® VIRTUAL Machining, he has a reliable NC code-based simulation at his disposal. Looking ahead, Iwanow plans to use hyperMILL®’s automation capabilities to further optimize processes and CAM programming efficiency.
Your journey toward CAM innovation begins here, too.
Take your manufacturing to the next level. Talk to us and discover all the possibilities.
Success in the World Cup
Since 2024, a professional race team has been competing with the Fracebike at World Cup and World Championship events, including the World Championships in Andorra. As early as 2025, Fracebike athletes achieved success at the June World Cup race in Leogang, Austria. German U19 champion Marlena Rieger is also part of the team and competed in Leogang. “The construction of the Fracebike is outstanding. The high stiffness enables incredible cornering speed,” she says. The outlook for upcoming races, including the European Cup, is very promising.
The downhill bike of German U19 champion Marlena Rieger at the World Cup race in Leogang in June 2025.
Small series production planned
A small series of the Fracebike is scheduled for production this year, much to the excitement of the downhill community. “There is strong interest in the scene. Demand shows us we are on the right path,” Iwanow explains. The Fracebike is evolving from a visionary one-off project into a small series solution for ambitious riders.
Special project, a unique enduro bike
A special collaboration between CNC Future Technics and OPEN MIND has resulted in a custom milled enduro bike presented as an award to OPEN MIND’s CTO, Dr. Josef Koch, a passionate mountain biker. The design was developed by Davide Ciarloni from the OPEN MIND CAD/CAM team together with Ralf Mauch, Senior Engineer Product Innovation at OPEN MIND, who also created the NC programs for the bike. The unique piece was manufactured on one of the Hermle machining centers at CNC Future Technics.
