Sturdy has launched two new titanium bicycles, the Fosse and the Drove, while simultaneously transitioning all manufacturing to its Somerset workshop.
By moving from external 3D-printing suppliers to in-house CNC machining, the brand aims to solve long-standing development bottlenecks and improve control over frame quality and design iterations.
For years, Sturdy was synonymous with the early adoption of additive titanium manufacturing. However, relying on external suppliers for 3D-printed components delayed the development cycle. Any design tweak required a feedback loop with third-party vendors, creating turnaround times that Chief Engineer Tom Sturdy described as a limiting factor, BikeRadar reported.
The brand has now invested in two state-of-the-art CNC machines at its Frome headquarters. By machining components from high-grade solid titanium billets, Sturdy no longer relies on the hand-finishing of 3D-printed parts, which often required secondary labor to meet quality standards.
“With 3D-printed parts, yes, the additive printing is created without human hands, they then need to be finished by hand, which is incredibly time consuming and you’re relying on the quality of the finishers’ work,” Jack Watney told BikeRadar.
The two new models represent a distinct shift in the brand’s design philosophy. The Fosse, named after the Roman road running near the Somerset workshop, is optimized for endurance riding with an endurance-friendly geometry and 38mm tire clearance. While the bike currently ships with an ENVE IN-Route fork, Sturdy is developing a proprietary all-titanium fork, scheduled for release in 2027.
The Drove, meanwhile, targets the gravel segment with a 55mm tire clearance and a geometry designed for stability on rough tracks. The frame features extensive mounting options, including triple bottle bosses and top tube mounts. Both bikes utilize T47-68 threaded bottom brackets and modular brake mounts on the chainstays, allowing for adjustments without the need for additional adapters or complex machining.
Bringing production in-house has allowed the team to create their own tooling, including custom jigs and carriers for the welding process. This vertical integration extends to the finishing process, where the company has moved from anodizing to Cerakote. This polymer-ceramic composite is applied as a thin 25-micron film, providing increased resistance to abrasion, chemicals, and UV degradation compared to traditional finishes.
To streamline the customer experience, Sturdy is moving away from the overhead of fully custom builds where possible. The new sizing matrix offers 18 distinct configurations by combining six frame sizes with three stack-height options. An online Size Selector tool allows users to input their current geometry and fit data to determine the optimal configuration before placing an order.
The build kits for both models emphasize durability and serviceability. By incorporating phosphor-bronze threaded inserts into the dropouts and using titanium thru-axles, the design prioritizes long-term material integrity. The following table highlights the primary differences between the two new platforms:
| Feature | Fosse | Drove |
|---|---|---|
| Intended Use | Endurance/Road | Gravel |
| Max Tire Clearance | 38mm (frame) | 55mm (frame) |
| Fork Clearance | 35mm (ENVE) | 50mm (ENVE) |
| Brake Rotor Compatibility | 140/160mm | 160/180mm |
Pricing for the SRAM Force-equipped Fosse starts at £4,511.60, while the Drove is priced from £4,137.60. Both models include titanium stems and seatposts machined in-house as standard equipment. The Drove is slated to be unveiled at the Rouleur Live show in London, starting today.
“The bronze inserts may add a very small amount of weight over steel or alloys, but they’re very strong and won’t bind,” Tom Sturdy said during the visit, emphasizing that the focus remains on the owner’s long-term experience with the hardware.
