Kawasaki KX450 3D Core Looks Almost Toy-Like, But Seriously Imposing at the Same Time

Given his artsy inclinations and in-depth knowledge of what makes a bike go fast, it should come as no surprise that he eventually tried his hand at customization. Instances when he had the time to tackle such ventures were few and far between, yet he's nailed them every single time. That being said, the project we’re about to look at is arguably the raddest thing ever built by Alvaro’s capable hands.

Dubbed the 3D Core, this otherworldly showstopper started out as a bone-stock Kawasaki KX450 that was brand-new when purchased by our protagonist. The transformation process took place toward the end of 2018, but the outcome will be worth looking at for many years to come. With this project, the main goal revolved around the extensive use of 3D printing technology for the bodywork.

The author’s primary source of inspiration was the Malaguti Grizzly dirt bike from the eighties – the machine that made him fall in love with motorcycles in the first place. He was just three years old at the time, but the memory of that two-wheeled specimen stuck with him to this very day. With a clear idea of what he wanted to achieve here, Signor Dal Farra laid out a concrete plan and dove straight in.

First things first, he eliminated each and every piece of stock bodywork he could get his hands on, along with the KX450’s wheels, suspension, and exhaust system. Collaborating with Codoro Studio, Alvaro came up with a concept that saw the Kawi dressed up in a perforated attire that looks as if it’s made of mesh. Then, he turned to Skorpion Engineering to have the parts 3D-printed by way of HP Multi Jet Fusion technology.

To call the end result mesmerizing would be a gross understatement, as it is unlike anything we’ve ever seen before. The mesh theme is present on everything from the fuel tank cover, side panels, and tail section to the front fairing and high-mounted fender. A stunning Blackbird Racing saddle accompanies the KX450’s new overalls, and the whole shebang rolls on aftermarket wheels wrapped in Dunlop knobbies.

For improved stopping power, the brakes were upgraded with higher-spec paraphernalia on both ends. Some comprehensive suspension mods were also on the menu, all carried out by the talented Tiziano Monti for the best possible result. Alvaro didn’t mention the precise details of the work done here, but you can be fairly certain that it’s top-notch.

With the running gear and bodywork fabrication taken care of, the major structural changes were pretty much done. As such, the project’s author turned his attention to the engine, enrolling the help of a trusted mechanic by the name of Andrea Casagrande. Together they fitted the single-cylinder mill with an assortment of Athena GET internals, seeking to extract every last drop of performance.

Exhaust gases are routed through stainless-steel pipework developed by Zard, and the gearbox has been paired with a premium STM clutch. This item was linked to Sunstar sprockets and a fresh drive chain, while the laser engravements on the swingarm were executed by Piazza Rosa. With the transformation process slowly coming to an end, Alvaro Dal Farra proceeded to address the finishing touches before calling it a day.

Various components have either been anodized red or blue, including the forks, wheel hubs, and control levers. This part of the makeover was assigned to Dedo Racing, while the motorcycle’s bodywork got painted by Carrozzeria De Bona Paolo and Michele Battistin. The paint job is an all-black affair for the most part, with red and blue highlights gracefully appearing in various places.

These contrasting hues are the main reference to the Malaguti Grizzly we’ve mentioned earlier, and the way they complement the black base and one another is absolutely delightful. With the finishing touches applied, Alvaro could finally sit back and admire his work in its full glory. The bike does an excellent job at showcasing what can be achieved when 3D printing technology is used at its full potential.

Although Dal Farra was the man with the plan on this build, a lot of credit ought to be given to the other artisans who took part in the customization process. Building the 3D Core was a team effort after all, and everyone involved played a crucial role in making it a reality. If the rise of new fabrication techniques means we’ll see many more craftsmen pushing the envelope like this, the custom scene has a very bright future!