Applied technologyMaterials & prototyping
Developing ready-to-race motorcycles E
very year, KTM Sportmotorcycle of Austria produces 110,000 high performance ready- to-race motorcycles. However, motorsport
is one of the toughest environments, and a part-failure due to a material or design defect can have serious implications. Helmut Gröbner, who is KTM group leader
for plastic components and heads-up a team of ten designers, explains that the pressure on the product development team is enormous – a plastic part approved for production needs to be 100% right. A new part is initially developed as a 3D
CAD model in ProEngineer Wildfire and then immediately subjected to extensive static and dynamic finite element stress analysis. When the CAD design is finalised, the company uses Moldflow to simulate the injection-moulding process. Only then can a prototype part be made for physical ‘real-world’ testing – KTM shorthand for conditions most people and motorcycles would never encounter. The only way to test the part is to make it
and subject it to extremes of stress, tempera- ture, load, etc., and the prototype should be as close to the final production version as possible, both in terms of mechanical quali- ties and also material. “Our first project with Proto Labs’ rapid
injection moulding service Protomold was a cover for a silencer on the exhaust,” said Gröbner. “Our budget for tooling was only €25-30,000 and we couldn’t risk going straight to production with a new design. “Time was also short, but a colleague
remembered seeing an advertisement for Proto Labs. So, we gave it a go, took delivery of the prototype, and in testing quickly discovered
that the part we had designed in plastic wasn’t durable enough. Eventually, we decided to make the part from metal, but had we not made the prototype with the help of Proto Labs, we would have wasted a great deal of time and money and we may well have ended up with a sub-standard part on the bike.” KTM’s second opportunity to work with
Proto Labs came soon after this, when the company was optimising the design of a filter compartment cover, which had previously been made of metal. The cover needed to open quickly without the need for a tool, but would also be secure enough that strong vibrations couldn’t loosen it. Gröbner said: “Proto Labs’ Protomold service
came to our rescue again. We made our first part, which immediately showed up problems with the fit and the securing mechanism. We made some design revisions and with the second part everything was perfect. In just five weeks we had tried two versions, finalised the design and taken delivery of 5,000 finished parts of production quality. Proto Labs even had sufficient material in stock, so there was no delay. Our production launch was flawless and the solution to the filter box cover was found to be perfect.” Most of the motorcycles, however, have to be
road ready, which means parts must meet high standards for TÜV certification. “We designed a new grab handle for pillion passengers. The fundamental question was whether to use plastic or metal, and if we did use plastic, would the part achieve the required strength. Of course TÜV tests only finished, production parts, which we were able to submit by making them with Protomold. The parts passed the
Copyright photographer: KTM
rigorous tests and are now in full production.” The next challenge came just three months
ahead of the INTERMOT trade show when the company decided to create a new rear-view mirror for the KTM 1190 Adventure, a year ahead of schedule. “Usually, you need a full year for a design
process from concept to production, including technical inspection,” commented Gröbner. “In this case, our tight deadline was only met because of Protomold. We designed and took delivery of parts that were inspected and passed by TÜV before being fitted to the bike at INTERMOT.” Proto Labs
www.protolabs.co.uk
Enter 200 New eco concept car relies on lightweight recyclable material A
new eco concept car from Toyota and Studio Massaud – the ME.WE – is
being described as compact, efficient and stylish. Its design is said to combine the latest tech- nologies to offer an attractive yet practical vehicle that answers some of the current economic and environmental challenges. ARPRO material has been
used in automotive applications for several years, from passive safety products such as side impact energy absorbers in door panels, head restraints and seat cores, seating and knee protection, to stowage applications. Here, the exceptional strength to weight ratio enables storage of tool kits, boot liners, load floors and console components. For the first time, however, ARPRO has also been selected for its visual
appeal. The ME.WE features extensive amounts of ARPRO internally and externally, to offer five key benefits. Being a lightweight material solution, in automotive applications like the ME.WE
it can result in fuel savings. Comparing the ME.WE with a traditional car of the same size, the use of ARPRO for the body panels means overall weight is reduced by 20%, which has considerable impact on the energy efficiency of the vehicle. The material also offers a combination of physical properties, allowing it to be
compressed and absorb significant energy without failing – on multiple occasions – while being able to reliably and consistently withstand impacts from different directions.
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The ME.WE utilises ARPRO in the side panels and for the bumper of the vehicle, specifically for impact protection benefits, making it safer for the driver, passengers, other road users and pedestrians. It is also a ‘clean’ material that is resistant to chemicals and liquids, making it easier to maintain, while promoting a cleaner, safer vehicle environment. The material can be easily moulded into any 3D shape. This is a benefit to the ME.WE design as it makes it customisable – it can be a pickup, convertible, off-roader and small city car all in one, while still enabling Toyota ease of assembly and component consolidation. The exterior surface aesthetic of the ME.WE is integral to the ARPRO panel, enabling the final vehicle design to be adapted to personal tastes – customers can choose which colour they would like, as well as what pattern or design. Furthermore, as ARPRO is 100% recyclable, the
carbon footprint of the ME.WE is markedly lower than traditional design vehicles, claims the company. Paul Compton, JSP president and chief execu-
tive officer, Europe, Middle-East and Africa, said that the car “showcases how ARPRO can be a versatile solution offering a myriad of benefits –
from efficiency and safety advantages, to new innovations in customising vehicle exteriors. It is a completely different approach to vehicle design and manufacturing, which is extremely exciting, and we are thrilled to be selected to partner Toyota and Studio Massaud in the development of this stunning concept.” ARPRO
www.ARPRO.com
Enter 201 JUNE 2013 Design Solutions
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