PRODUCT DEVELOPMENT | TECHNOLOGY
“The rapid increase in order intake is being fuelled by more customers, across varied industry sectors, now realising the extensive possibilities to proto- type parts with complex geometries cost-effectively using 3D printing technology,” says Daniel Cohn, Managing Director of the 3D printing business Proto Labs GmbH in Feldkirchen, Germany. “For certain parts, the only possible option is to manu- facture using this technology. For example, our Eschenlohe facility is certified with EN ISO 13485:2012 quality management standards. For customers, they benefit from our technical capabili- ties to manufacture specific medical devices using 3D printing DMLS technology, including parts approved for human implantation.” The company has also introduced liquid silicone rubber (LSR) capabilities to support the manufac- turer of larger injection moulded parts. Proto Labs says that customers can now order LSR moulded parts to a maximum part outline of 304×203×100mm. Technically, this can produce a part with maximum projected mould area of 31,200mm² and maximum part volume of 217,000mm³. Proto Labs has recently been involved with the development of a new vehicle bicycle carrier for Auxtail, including the plastic bike carrier tyre grip, a key component in the design. The growing popularity of cycling has led to an increased demand for vehicle bike carriers so people can transport their bikes wherever they go. However, identifying a carrier suitable for a specific model of car and bicycle is not always easy. The problem, according to design engineer Craig Broadbent, founder of Auxtail, is that traditional methods of fixing a bike and carrier to a car are not ideal. He believed that a new way had to be found - not just for the practicalities of usability, but also to transport bikes safely for all road users. Recognis- ing this as a business opportunity, Broadbent established Auxtail in May 2016 to develop a more secure and effective bike carrier solution. The result was the EasyRide2. In place of a tow bar or tailgate/ boot mount, EasyRide2 is con- nected to a fitting attached to the vehicle’s hidden, but strong bumper beam. This means the carrier can support more weight than the traditional tow bar approach, is also lighter and less costly to produce. Having completed the design and specification for the EasyRide2’s structure, the
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challenge for Auxtail moved on to how to secure bikes to the carrier. In order to protect the cycle frame, the decision was made to use wheels and tyres as the anchor points. A more exacting design process with a tyre grip combining ratchet handle and release facility, EasyRide2 also had to accom- modate different sizes of wheels and tyres. Given the essential safety considerations, Auxtail deter- mined that the design would require the comple- tion of a managed prototype programme. Only then, with a fully tested product, could injection moulding tooling and manufacturing commence. Auxtail designed the tyre grip using CAD and finite element analysis (FEA) tools and reached the stage where prototyping could start for the three constituent components. The company was able to define the material, process requirements and delivery time frame – feeding the CAD models directly to Proto Labs online. “We knew that in addition to carrying out
simulation tests, we would have to test the proto- type in the field,” says Craig Broadbent. “To make this work successfully and to give us the most accurate outcome, it was important for the EasyRide2 prototype to reflect production level qualities as closely as possible. In the event, Proto Labs produced a product with a 90% match in terms of material qualities. For us this was an excellent outcome to take us forward.” The prototype EasyRide2 was taken to the Millbrook Proving Ground in the UK for durability testing. With this stage completed satisfactorily, Auxtail says that it was able to move to the manufacturing and injection moulding prepara- tions with confidence.
US additive manufacturing company Carbon has launched
October 2017 | INJECTION WORLD 67
Above: Auxtail developed a new vehicle bicycle carrier, incorporating key plastic components, using 3D printing of prototype parts
Left: Prototype part made with Carbon’s Clip technology and cyanate ester resin
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