Development of a custom BMX bike frame for a local team. The goal was the production of approx 10 units. The proposed concept was a unique design that fits all riders. 3D design was made in collaboration with team members to capture most of the personal inputs. Material sourcing was a challenge since CrMo thin wall tubing is not available everywhere nor in every sizes. Production tooling including a welding jig had to be built especially for the job. The concept developed is the following: riders take part in the preparation of the steel part of the frame (cutting, filing, sanding…) based on 1:1 scaled 2D drawings, then the welding is made by an experienced welder.