Versatility and speed of 3D printing used as end parts for university racing team

“We have decided to bet on 3D printing because of its versatility and speed"

“We have decided to bet on 3D printing because of its versatility and speed. We are working on the development of an electric motorcycle, whose geometries differ greatly from those of a traditional motorcycle and 3D printing allowed us to make a completely customised fairing that perfectly adapted to the measurements of our vehicle. In terms of materials, the JCR work a very wide range, which allowed us to work with a plastic that worked well aerodynamically, was not excessively heavy, and worked well mechanically (being able to get to mechanise if necessary). Finally, the deadlines of our project force us to work with very fast solutions. In less than a week we received the pieces, compared to the months that are required to obtain the same pieces through a traditional process.”

— Daniel Suñén Angós,
Propulsion Advisor, Team Leader



 

Introduction

MotoStudent is a motorcycle racing challenge at international level, in both design and speed. A challenge in which more than 40 groups of students from all over the world will participate. The objective of this competition is to design, manufacture and evaluate a prototype competition bike. Said motorcycle will be tested and will have its final evaluation at the Motorland de Aragón circuit. The competition represents a challenge for the students, since they will have to demonstrate their creativity and ability to innovate for three semesters; as well as his engineering skills.

EUPLA Racing Team is a university team created to compete in the 4th edition of Motostudent in the electrical category. The group consists of eight students from the Polytechnic University School of La Almunia (EUPLA).

The Polytechnic University School of the Almunia de Doña Godina (EUPLA) is a public centre attached to the University of Zaragoza, which is located in the town of La Almunia de Doña Godina in the province of Zaragoza, in the Autonomous Community of Aragon.

Solution

  • Optimisation of the initial design to be 3D printed.
  • Generation of printing codes: Using CAM Simplify3D software in order to programme the printing process according to the settings listed above.
  • Manufacturing using a large format JCR 1000 3D printer: The printing code generated is loaded into the printer to launch the manufacture of black EP material, creating the various parts as separate prints.
  • Cleaning of the supports: removal of support structures, previously created and optimised with the help of the Simplify3D software and the experience of the technician responsible for generating a printing code.
  • After the simple removal of the support piece, the connection between the support piece and the material is sanded to remove any residue material from the support.
  • Assembly and post-processing.

Production process

The front fairing has been divided into four parts for the manufacture process:

  • Keel
  • Left side fairing
  • Right side fairing
  • Mask

Other part in the fairing is the tail/seat, divided into two parts for manufacturing. Having manufactured and removed the support, the following step was to assemble the parts that had been separated as part of the design process. To facilitate assembly, the different parts include a series of tabs allowing for a surface overlap between the different parts to reinforce the point of union. Resin was used to join the parts, and a resin with glass fibre was used to reinforce the joints and some parts of pieces which constitute areas of concentrated force, such as the fairing attached to the chassis, which supports the pilot’s weight.

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