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Altair > Case Studies > Revolutionizing Lightweight Design: The Case of Airbus APWorks Light Rider

Revolutionizing Lightweight Design: The Case of Airbus APWorks Light Rider

Technology Category

Sensors - Optical Sensors

Applicable Industries

Aerospace
Automotive

Applicable Functions

Product Research & Development

Use Cases

Additive Manufacturing
Rapid Prototyping

Services

System Integration

The Challenge

The challenge was to create a lightweight, high-performance product using additive manufacturing or 3D printing. The aerospace industry has been a pioneer in this field, and other sectors such as the automotive industry are following suit. The goal was to leverage the benefits of additive manufacturing, such as weight reduction and the ability to create complex geometries, to create an innovative product. The product in question was the Airbus APWorks Light Rider, the world's first 3D printed motorcycle prototype. The complex branched hollow structure of the Light Rider could not be realized with conventional manufacturing methods such as welding or milling. The challenge was to use topology optimization and a new material developed in-house by Airbus to create this innovative design.

About The Customer

The customer in this case is Airbus APWorks GmbH, a wholly owned subsidiary of the Airbus Group. APWorks stands for the development of completely new components and products by leveraging the triad of re-engineering, material optimization, and 3D printing. The company aims to achieve weight and cost savings, reduce assembly time, and integrate new and additional functions in parts and components. APWorks is committed to a simulation-driven design process, which delivers innovative, reliable design results. The company's engineers are experienced in the use of the HyperWorks suite and rely on the results the Altair products provide.

The Solution

The solution involved using topology optimization and a simulation-driven design process with HyperWorks. The Light Rider was developed by APWorks as a design study to showcase the manifold opportunities of metal 3D printing to existing and potential customers. The frame design of the electrical motorcycle was based on a structural optimization inspired by natural principles. In addition to topology optimization, the material Scalmalloy®, a high-performance aluminum alloy developed by Airbus, was a success factor. The material is not only corrosion-resistant but combines the light weight of aluminum with almost the specific strength of titanium. For the frame design, APWorks engineers used a variety of simulation tools from the Altair HyperWorks Suite. The engineers had to overcome three major challenges: creation of the optimal shape based on given boundary conditions, derivation of the geometry from the optimization results, and handling of 3D printing specific manufacturing constraints.

Operational Impact

The Light Rider prototype showcases the ideal approach of leveraging the symbiosis of topology optimization, novel materials, and additive manufacturing as well as a simulation-driven design process to benefit from the full weight and performance potential. The design proposal derives from natural principles and serves as a template for an extraordinary design concept. Topology optimization is especially well suited for additive manufacturing, because it puts material only where it is needed – an approach which can be realized very well in 3D printing. The result is a revolutionary lightweight design that could not have been achieved with traditional manufacturing methods.

Quantitative Benefit