Preserving Victorian Engineering Through Digital Manufacturing

The iconic “Penny Farthing” is one of the most recognisable bicycles in history, instantly identifiable by its oversized front wheel and much smaller rear wheel. However, despite the name becoming widely associated with the design, “Penny Farthing” was never actually its original name.

When these machines first appeared during the late 19th century, they were simply referred to as bicycles, and later became known more formally as the ordinary bicycle. The now-famous nickname only emerged later, inspired by the visual similarity between the large and small wheels and the size difference between the old British penny and farthing coins.

This particular example was originally built in 1879 by Humber, Marriott & Cooper, a company that would later become well known within British engineering and automotive history under the Humber name. Like many surviving examples of Victorian engineering, the bicycle represents not only an important stage in transport history but also a remarkable example of early mechanical design and manufacturing.

Over time, however, many original components on historic vehicles and machinery inevitably deteriorate through age, wear, and use. In this case, the original pedal foot rubbers had become worn and required replacement in order to preserve both the functionality and authenticity of the bicycle. Unfortunately, sourcing original replacement parts for machines of this age is rarely straightforward, with many components no longer commercially available in any form.

To help recreate the missing parts, BritForge3D used modern digital manufacturing techniques to produce accurate replacement pedal rubbers while still retaining the appearance and character of the originals. The process began by carefully assessing and measuring the surviving components so that replacement versions could be modelled accurately using CAD software.

The replacement pedal rubbers were then recreated in Fusion 360, allowing detailed 3D models to be produced and refined before manufacturing began. Using CAD modelling software made it possible to recreate the shape, dimensions, and mounting features of the original parts while ensuring the final replacements would fit correctly once installed onto the bicycle.

Process, Material Selection, Final Thoughts

The material selection also played an important role within the project. The replacement parts were produced using TPU, a flexible and durable 3D printing material commonly used where impact resistance and elasticity are required. Unlike rigid plastics, TPU provides a rubber-like flexibility, making it particularly well suited for components such as pedal rubbers that experience repeated contact and movement during use.

Using 3D printing technology allowed the replacement components to be manufactured efficiently without requiring expensive tooling or mould production. Traditional manufacturing methods for low-volume heritage parts can often be prohibitively expensive, particularly when only a small number of components are required. By contrast, additive manufacturing provides a practical and cost-effective solution for reproducing rare or obsolete parts in limited quantities.

Projects such as this highlight how modern 3D scanning, CAD modelling, and additive manufacturing technologies are increasingly being used within the heritage and restoration sectors. In many cases, these tools provide an opportunity to recreate parts that would otherwise be extremely difficult to source, helping preserve historically important machinery and vehicles for future generations.

The Penny Farthing itself also represents an important stage in the evolution of bicycle engineering. While visually striking, the design had significant limitations, particularly in terms of balance, safety, and gearing. Riders sat high above the ground, and because the pedals were connected directly to the large front wheel, stopping suddenly or striking uneven ground could easily result in serious accidents.

By the late 1880s, British inventor James Starley introduced the chain-driven rear-wheel bicycle, a development that would eventually lead to the modern “safety bicycle” design still used today. By separating pedal speed from wheel size through the use of chain gearing, bicycles could use smaller wheels while remaining faster, safer, and easier to ride. This innovation quickly made the ordinary bicycle obsolete, despite its iconic appearance and popularity during the Victorian era.

Today, surviving Penny Farthings remain an important reminder of early engineering innovation and the rapid development of personal transport during the Industrial Revolution. Restoring and preserving these machines is not simply about maintaining historic objects. It is also about preserving the craftsmanship, mechanical thinking, and engineering heritage that shaped modern transportation.

Projects such as this demonstrate how modern manufacturing technologies can now work alongside traditional restoration methods to help preserve engineering history. By combining CAD modelling, TPU 3D printing, and careful reproduction techniques, it becomes possible to recreate missing or worn components while still respecting the originality and character of the historic machine itself.