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Revolutionizing Motorcycle Design with 3D Printing: The Light Rider Case Study
Technology Category
- Sensors - Optical Sensors
Applicable Industries
- Aerospace
- Automotive
Applicable Functions
- Procurement
- Product Research & Development
Use Cases
- Additive Manufacturing
- Virtual Prototyping & Product Testing
Services
- System Integration
The Challenge
Airbus, one of the largest aircraft manufacturers, has always been keen on weight saving as it directly impacts fuel consumption, cost, and carbon emissions. To further explore advanced manufacturing technologies, Airbus set up APWorks in 2013, a subsidiary dedicated to design, materials, and 3D printing. However, due to the confidential nature of customer projects, APWorks found it challenging to tangibly showcase the possibilities of parts designed specifically for Additive Layer Manufacturing (ALM). They needed a project that would allow them to demonstrate the potential of ALM, and decided on creating an electric motorcycle. The challenge was to design and produce a motorcycle that was significantly lighter than traditional models, while maintaining strength and durability.
About The Customer
The customer in this case is APWorks, a 100% subsidiary of Airbus. APWorks was set up in 2013 with a production facility in Munich to explore advanced manufacturing technologies and work on innovative projects for Airbus Group. The company operates independently, offering expertise in design, materials, and 3D printing. APWorks is dedicated to exploring the potential of ALM, and the Light Rider project was an internal initiative to showcase the possibilities of parts designed specifically for ALM. The company is also involved in other projects, including a bionic aircraft cabin partition and the development of the first fully 3D printed liquid-to-liquid heat exchanger for robotic and automotive applications.
The Solution
APWorks used its proprietary material, Scalmalloy, an aluminium alloy developed specifically for ALM technologies, to construct the frame of the motorcycle. The engineers used a simulation tool from Altair called OptiStruct during the concept phase of the development process in an approach known as topology optimisation. This allowed them to optimise material layout within a given design space, for a given set of loads and boundary conditions to achieve the required performance targets. The engineers also created a hollow frame to further reduce mass and provide a means of hiding cables and pipes. The frame was divided into 14 separate sections for printing, each designed to withstand all the loads. Once all the parts were printed, they were TIG (tungsten inert gas) welded together. The final product, named the Light Rider, weighed just 35kg, with the frame being a mere 6kg.
Operational Impact
Quantitative Benefit
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