Motorbike part revs up Additive Manufacturing process
The MTC worked with GRM and K-Tech on a project to investigate the weight-saving of an additive manufactured motorbike part.
“The MTC's experience in additive manufacturing technologies has been a great help in ensuring our tools compliment these emerging technologies.”
Martin Gambling, Managing Director at GRM Consulting Ltd.
The Challenge
- Design SMEs GRM and K-Tech were keen to further investigate the capability of Additive Manufacturing (AM)
- In order to fully utilise the benefits of AM for product improvement, GRM and K-Tech were looking to develop knowledge and expertise in considerations for Design for AM
- K-Tech had previously designed and manufactured a motorbike fork end, and were looking to improve this product
MTC’s Solution
- Working with GRM using TruForm topology optimisation, the MTC facilitated fast iteration of designs to optimise the motorbike fork
- Two motorbike forks were manufactured in a titanium alloy using Electron Beam Melting (EBM)
- The MTC performed non destructive evaluation (NDE) via structured light scanning. This was carried out using GOM for geometric conformance and X-ray computed tomography for defect detection
The Outcome
- Electron beam additive manufactured components with assurance of quality via NDE
- Optimisation of component design, achieving a 50g weight saving per component. The switch to titanium improved fracture toughness.
Benefits to the client
- Fast iteration and design change implementation throughout project
- Product and process knowledge captured for use in future GRM and K-Tech programmes
- Transferable capability and knowledge obtained as a result
“Through the support of the MTC, GRM were able to learn, apply and demonstrate our TruForm design tool to great success.”
Martin Gambling, Managing Director at GRM Consulting Ltd.
