Altair > Case Studies > Revolutionizing Motorcycle Design with 3D Printing: The Light Rider Case Study

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

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 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.

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

The Light Rider project has allowed APWorks to demonstrate the potential of ALM in a tangible way. The motorcycle, despite its lightweight, is as strong or possibly stronger than traditionally manufactured models. The use of Scalmalloy and the ALM process has enabled the creation of a thin and complex structure that would not have been possible with traditional manufacturing methods. The project has also showcased the potential of topology optimisation software, lightweight materials, and 3D printing. The success of the Light Rider project has opened up opportunities for optimised 3D printed parts in various industries, revolutionising the design and manufacturing process.

Quantitative Benefit

The Light Rider weighs just 35kg, 30% lighter than a motorcycle with a traditionally manufactured frame.
The frame of the Light Rider is a mere 6kg.
The Light Rider can reach 80km/h in a few seconds with a 6kW electric motor.