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How THOK’s 3D-Printed Metal Prototype Became the Carbon TP4 eMTB

THOK’s TP4 began as a rideable 3D-printed aluminum prototype used to develop geometry, suspension and component integration before production in carbon.
Entry653 Date Time4 min MechanicCarCody Team
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THOK used a rideable, 3D-printed aluminum prototype to develop the TP4, then built the production eMTB with a carbon frame. The metal bike was a development tool—not the material used for the finished TP4—and let the company assess geometry, suspension and component integration before settling on production solutions.

What the THOK TP4 prototype was—and what it was not

THOK says TP4 stands for “THOK Project Four” and that development took about a year and a half. Its first functional prototype was a rideable aluminum eMTB made using selective laser melting (SLM), a metal 3D-printing process. The production TP4 became a carbon-framed bike.

THOK says the prototype let its team evaluate geometry, suspension and component integration while skipping stages of conventional prototyping. It also helped the company choose carbon for production and refine technical solutions; THOK notes that some production-design solutions differ substantially from those on the first prototype. New Atlas likewise reported in December 2024 that an aluminum-and-silicon-alloy prototype preceded the carbon TP4-R. THOK’s TP4 project information and New Atlas’s December 2024 report provide the development and launch context.

THOK calls the TP4 the world’s first carbon full-suspension e-bike whose first functional prototype used 3D printing. That is the manufacturer’s description; the available sources do not independently establish the “world’s first” claim.

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Where THOK positions the TP4

THOK describes the TP4 as an “enhanced all-mountain with an enduro side to it.” The official limited-edition specification gives it 160 mm of front travel and 150 mm of rear travel. Those figures and the bike’s positioning suggest a design aimed at demanding trail riding, but they do not establish how it performs on a particular trail or for a particular rider.

A flip-chip lets the rider alter head- and seat-tube angles and lower the bottom bracket, changing the geometry for different riding styles and terrain. The official page lists 29-inch wheels with compatibility for a 27.5-inch rear wheel, as well as four frame sizes, S through XL. It publishes separate high- and low-position geometry measurements; fit decisions should therefore account for frame size, reach, flip-chip position and wheel setup rather than relying on the size label alone. Consult THOK’s geometry and limited-edition specifications for the actual measurements.

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Battery and motor details depend on the TP4 version

New Atlas’s December 5, 2024 launch report describes the standard TP4-R with a fifth-generation Bosch Performance Line CX motor, rated up to 85 Nm of torque, and a removable 800 Wh battery. The report says the bike is also compatible with 600 Wh and 400 Wh batteries and an optional 250 Wh Bosch PowerMore bottle-style range extender. These are reported launch specifications, not a guarantee that every model year or regional configuration includes the same equipment.

THOK’s limited-edition page separately lists a Bosch Performance Line CX rated at 250 W and 85 Nm, an integrated 800 Wh battery compatible with 600 Wh and 400 Wh packs, and optional PowerMore 250 Wh extender. Battery compatibility and included capacity should be confirmed for the exact bike being considered; the standard and limited-edition descriptions are not interchangeable.

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TP4-R and Limited Edition are different builds

The component lists below describe different versions and sources. New Atlas’s TP4-R specification is a December 2024 launch snapshot; THOK’s detailed specification is for the limited edition. Confirm the current model-year build with THOK or a local authorized dealer.

Item TP4-R launch report TP4 Limited Edition
Suspension Fox Float 36 Performance fork and custom-tuned Float X shock (New Atlas, Dec. 5, 2024) Öhlins suspension (THOK limited-edition page)
Brakes Magura MT5 four-piston brakes with 203 mm rotors (New Atlas, Dec. 5, 2024) Magura MT7 (THOK limited-edition page)
Wheels DT Swiss alloy rims (New Atlas, Dec. 5, 2024) DT Swiss HXC 1501 carbon wheels (THOK limited-edition page)
Transmission Shimano 12-speed gearing (New Atlas, Dec. 5, 2024) SRAM GX Eagle T-Type 12-speed (THOK limited-edition page)
Other reported equipment Schwalbe Albert Gravity Pro tires, dropper post and headset steering lock (New Atlas, Dec. 5, 2024) Renthal carbon handlebars and Schwalbe Albert Gravity Pro tires (THOK limited-edition page)

THOK says the TP4 Limited Edition was designed, manufactured, painted and assembled in Italy, and limits its production to 30 units. Its package contents include a suspension pump, multitool, rear UDH hanger set, bottle and cage, aluminum cup, keychain and stickers.

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How much did the TP4-R cost?

New Atlas reported a TP4-R launch price of €6,990 in December 2024. This is a historical launch price, not a current quote. The same article’s dollar conversion was approximate at the time and does not establish a current U.S. price or U.S. availability.

THOK’s manufacturer catalog displays TP4-family models including TP4, TP4-S, TP4-R and TP4 Limited Edition, with UK prices, battery capacities and weights. Those are regional catalog listings, and the page may not reflect current stock, prices or configurations. Check THOK or an authorized dealer in your country for the price and availability of the specific model year.

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What the prototype story tells a buyer

The unusual part of the TP4 story is the development sequence: THOK says it built and rode a metal 3D-printed prototype to study a full-suspension eMTB before moving to a carbon production frame. That explains the prototype’s role, but it is not evidence by itself of ride quality, durability or a safety certification. The available sources do not provide an independent ride test or a certification review.

For a purchase decision, focus on the exact bike in front of you: its size and reach, flip-chip setting, wheel configuration, battery capacity and component build. The TP4-R launch-report equipment should not be assumed to match the 30-unit Limited Edition, and neither historical launch pricing nor a regional catalog listing should be treated as a live local offer.

Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.

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