Bastion Archetype - Fusing 3D Printing, Carbon, and Aerodynamics
Explore the Bastion Archetype: an aerodynamic bike blending classic lugged style w/ 3D printed Ti & carbon. Wind tunnel tested, UDH, 34mm clearance. Limited edition.
In an era dominated by Kamm-tails and integrated cockpits, the timeless elegance of lugged frames with round(er) tubes often seems like a nostalgic choice, potentially sacrificing cutting-edge aerodynamic performance. However, Bastion Cycles, a small Australian company born from advanced manufacturing expertise, is challenging that dichotomy. With their newly announced Bastion Archetype platform, they aim to prove that classic beauty and wind-tunnel-proven speed can coexist.
From Automotive Engineering to Boutique Bicycles
Bastion Cycles itself is a relatively young company, founded roughly a decade ago (around 2015) by a trio of engineers: Ben Schultz, James Woolcock, and Dean McGeary. Their journey began uniquely, not in a traditional framebuilder's workshop, but within Toyota’s Technical Centre in Melbourne. Facing the facility's closure amidst a broader restructuring of the Australian auto industry, they saw an opportunity to pivot. Leveraging their deep knowledge of cutting-edge manufacturing techniques learned at Toyota, they founded Bastion.
Instead of traditional brazing, Bastion built its identity on a combination of 3D printed titanium lugs and filament-wound carbon fiber tubes – a technology borrowed from performance kayak paddles. This approach offered significant advantages: greater geometric customization with fewer production hurdles, easier scalability, and, perhaps most importantly, a distinctive aesthetic. Bastion bikes quickly became known for their beautiful blend of modern and timeless design – intricate, polished titanium lugs holding round carbon tubes, creating a romantic look updated with impossibly shaped, additive-manufactured joints.
The Aerodynamic Evolution: The Archetype
While aesthetically striking, this construction method traditionally meant riders chose the Bastion for its craftsmanship and unique look, implicitly accepting it wasn't optimized for slicing through the wind like contemporary aero superbikes. The Bastion Archetype marks a significant evolution, directly addressing this.
The core innovation lies in reshaping the components without abandoning the signature style. Bastion realized that neither 3D printed lugs nor filament-wound tubes require a perfectly round profile. The Archetype transitions these elements to incorporate NACA (National Advisory Committee for Aeronautics) aerodynamic profiles. This allows the bike to retain its classic lugged silhouette while significantly improving its aerodynamic efficiency.
As Co-CEO James Woolcock describes the philosophy behind the change, "Every surface and joint has been reimagined. We’ve leveraged over a decade of experience to refine finishes and create a frame that celebrates the raw beauty of our materials.” This meticulous attention extends even to the headbadge – a 3D printed titanium piece featuring an incredibly thin (0.05mm) etched stainless steel layer placed under the clear coat, specifically designed to ensure clean airflow over the headtube.
Quantifiable Gains in the Wind Tunnel
These aerodynamic refinements aren't just theoretical. Bastion subjected the Archetype to testing at the renowned Silverstone Sports Engineering Hub in the UK. According to the company, the results are substantial. Compared to previous iterations (implied), a complete Archetype build (specified with Shimano Dura-Ace Di2 and Partington R39/44 Wheels) demonstrated a drag reduction of 6–8 watts across yaw angles from 0–15° at 35 km/h – a speed Bastion notes is typical for their clientele. They state that for an average rider outputting 200 watts, this is a "significant advantage." The gains become even more pronounced at higher speeds, with Bastion claiming the Archetype reduced aerodynamic drag by an impressive 18–25 watts at 50 km/h.
Modern Features Beyond Aero
The Archetype isn't solely focused on speed; it also incorporates contemporary practical features. Tire clearance has been increased to accommodate up to 34mm tires, offering more comfort and versatility. Additionally, the frame now features a UDH (Universal Derailleur Hanger), simplifying drivetrain setup and potential repairs.
Exclusivity and Availability
Reflecting its high-tech construction and boutique nature, the Bastion Archetype is a limited-production model, with only 606 units planned globally. Demand appears high; Bastion reports that early access granted to existing customers and retailers has filled the order book until November 2025 (as of May 2025), with the first deliveries anticipated in late July 2025. They state that only 38 allocations remain available for delivery slots within 2025. While specific pricing wasn't released with the launch information, the limited nature and advanced manufacturing suggest a premium position.
Potential customers can now explore possibilities virtually. Coinciding with the launch, Bastion has made its previously deposit-locked "world-leading design configurator" publicly available on their website, allowing anyone to visualize their dream build.
The Bastion Archetype is available exclusively through Bastion directly and their network of approved global retail partners.
The Takeaway
The Bastion Archetype represents a compelling fusion of artistry, advanced engineering, and aerodynamic performance. It successfully retains the brand's signature classic aesthetic while integrating measurable speed advantages validated through wind tunnel testing. Combined with modern practicalities like wider tire clearance and UDH compatibility, it stands as a unique offering in the high-end road market. For riders seeking a bike that makes a statement both visually and against the clock, and who value cutting-edge, limited-production craftsmanship, the Archetype presents a fascinating, albeit exclusive, option.
