I dont know if you will get right properties from a resin printer. Even 100% infill might not be enough. Might be worth looking at your material and see how samples lab test and make sure you have a good margin of safety. Or you can tighten a sample up to 4nm or something and see if it creeps enough that you need to retighten it after a few weeks.

My $.02: Once you have the fit worked out using the home printer, get the functional ones made by someone with a nice high end machine. MJF parts are cheap and while glass filled nylons are 2x the price of standard Nylon12, I believe MJF Nylon12GB (also Pa12gb) are what the 3d printed headset parts used on pro bikes use.

Ive made some functional spacers. What do you mean one or two piece? Like split spacers vs. not? Or uses either a CF or metal insert for compressive strength?

Regarding the latter, if the spacers are under the stem they need to hold preload. It’s not a lot of force but its safety critical to prevent damage to the steerer. I am pretty conservative with this stuff but personally would only make spacers without an insert out of something like MJF Nylon12GB. It’s the 3d printed material closest in properties to the injection molded nylon 66 that OEM solutions seem to use.

Plenty of examples of 3d printed spacers from Extralite, etc failing.

To answer the question: 30mm tires are the official spec. I've seen 32mm tires on some but i think that's probably it.

I also think people don't realize that Ventum has done pretty well on the Tri (Z and One) and Gravel (GS1) side and are bigger than a lot of people think. Their frames are definitely not open molds. Are they equivalent to the best brands? Probably not. How much of their engineering is in house vs. outsourced? No idea. But there are a few shops near me that build and sell them and their riders seem mostly happy with what they have.

There have been a couple of aethos clones on Alibaba on and off for the last few months, one with internal routing that look a lot like the superlight frame here. The only thing that held me back was that these kept getting delisted (big red flag) and I dont have room for another bike frame.

If they could make these clear a 35mm tire but keep the aethos-like geo, these would make a really great frame general use frame for everything from a bit of CX to commuting. Especially if they used a BB standard that was eccentric friendly.

Edit: I have no experience with this seller, but here are the links:
Internal routing through headset: https://www.alibaba.com/product-detail/2023-Lightest-Weight-650g-same-to_1600860750115.html?spm=a2700.shop_plgr.41413.3.39582af1cVmqH2
Internal routing through downtube: https://www.alibaba.com/product-detail/2023-Lightest-Weight-690g-same-to_1600861204788.html?spm=a2700.shop_plgr.41413.7.39582af1cVmqH2

I also realize the Ican version is different in terms of HT, FD cable exit and rear dropout.

Nextie ARX are another option worth looking into. They are front and rear specific profiles which is kind of interesting. There is a 49 / 54 and a newer and wider 60 / 65

I personally really like the WR50 from LB (i have had the flyweight version for as I weigh like 55-56kg) and have kept a pair over the course of a few years as many other wheels have come and gone. Not sure that build though fits OPs budget.

One thing to think about is that wheels sort of became a commodity for a while as everyone settled more or less settled on NACA profiles. I don't think that has been the case for several years and the brands pouring in the R&D are making better products. For example my Ascent Polaris 69mm deep wheels are significantly more predictable in crosswinds and faster than than my LB WR50. On the other side, I think my Roval CLX50 were faster wheels than my LB WR50s are; though they were hell for me to ride in crosswinds which is why the WR50 stayed and those went.

I would prefer 12t.

I want to be able to press in a few different bearings and see how they stand up to use / pressure washing etc, and 688 is a nice common size with options from the very expensive (e.g., enduro xd-15) down to the very cheap. So far, I have learned that ZTTO seems to use the 689 size.

I messaged a few aliexpress sellers i found using the the search terms you suggested. Thanks!

I have done a few transactions on Alibaba and I would be surprised if the total cost of er9 is less than $500 to your door if you live in a western country. Its often cheaper to buy things on Aliexpress simply because sellers on Alibaba are passing all the fees on to you. A recent purchase of 50 garmin inserts for example was $20 cheaper on Aliexpress than Alibaba from the same seller.

Given that my target price for batteries, RD, FD, and shifters/brakes for Rival AXS is ~$700, I dont think I am in the market for er9 or ERX either given that warranty support is important for groupsets.

Hi all, I think I might be able to help with solution to maintain preload. I have been working with the different internal headset routing systems for a while and have been running on my personal bikes a hybrid system using the Deda compression ring and a custom dust cover to mate to the FSA split spacer and ACR / SMR system. Some photos if what I have been working on are below.  I have also been working a generic fitment as well as one specific to the -17 Kalloy uno. All of those designs were designed to reduce stack and are electronic group only as cable housings can't make the tight bends required, but that doesn't have to be the case if more / different spacers are used.

I could adjust the skirt length and thickness of the dust cover to provide a better fit to bikes that do not use a countersunk dust cover, though the system would not have a seal other than what is on the bearing. I would also be willing to make an FSA ACR to Velobuild one piece handlebar adapter plate assuming that most of the frames use the same spacer stack and interface. I would need help getting some measurements of one of the spacers that fits into the bottom of the handlebar or send one to me (and be willing to try out a dust cover and adapter to make sure they fit)

I was previously on the Velobuild forums (2009-2011ish?) and you can find me on a few bike discords as well. This is also a hobby for me and I would price everything at cost + taxes. I will probably eventually open an etsy store or something and these would be about 30USD + shipping with everything MJF printed using Pa12GB + you would need to buy either the Deda headset or the compression ring.