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MATERIALS IN DESIGN & PROTOTYPING
PocketQube, designed in partnership with the European Space Agency (ESA). • ‘HADES’ & ‘EASAT’, twin 1.5p PocketQubes developed in Spain by AMSAT-EA and Hydra Space. They were designed for satellite communications between radio amateurs via a 145/435 MHz transponder.
• ‘SATTLA-2A & 2B’, an open source project developed by Ariel University in Israel. These 2p PocketQubes will utilise WiFi cards for extreme long-range link applicable to transmit video for over 600km in LOS conditions.
• ‘DELFI-PQ’, a 3p PocketQube developed in the Netherlands by TU Delft | Aerospace Engineering. This satellite is a tech demo mission testing a LOFAR payload and a laser retro reflector.
3D PRINTING VEHICLE PARTS In another application, ground mobility company Local Motors’ autonomous electric vehicle Olli 2.0 includes 3D printed parts manufactured by CRP Technology in Windform composite materials. The Modena-based company, which has been involved in professional 3D printing with Windform composite materials since 1996, was contacted by the EMEA management of Local Motors to build some parts mandatory in order to obtain individual approval for Europe. Carlo Iacovini, general manager EMEA,
Local Motors, stated: “Olli is operating in campuses, stadiums, industrial districts and local communities around the world. To approve deployments in Europe, it needed some additional components, not required in the US market.”
The windshield wipers and parts were among
these components, the company explains. According to Iacovini, a retrofit technique – or re- adaption process – was used to add the wipers. Olli 2.0’s design is characterised by a tall
rectangular pod with wide-set headlights and expansive windows nestled between a frame. The wiper arm could therefore not be positioned from above, but from the below side of the front window. So, the Local Motors’ Engineering Department designed a new front bumper with brackets for fixing both the wiper’s starter motor and the front wiper washer reservoir. However, during the assembly phase, the
team noticed that the motor protruded from the modified front bumper. “To avoid the issue we
Having identified the parts to manufacture – the motor cover and the washer reservoir flap valve of the wiper’s system – Local Motors turned to CRP Technology
FEATURE
therefore thought to add two coordinated covers, with the purpose of concealing the protruding part (the first cover) and protecting the pressure system of the washer reservoir from external agents (the second cover),” explained Iacovini. “For the wiper washer reservoir flap valve, we modified and adapted the design of the flap valve of the charging socket on Olli 2.0’s rear bumper. In this way we maintained homogeneity from the design point of view, and we positioned the water flap valve symmetrically to the charging one.” Having identified the parts to manufacture –
the motor cover and the washer reservoir flap valve of the wiper system – Local Motors turned to CRP Technology. Looking into the projects, CRP Technology experts opted to create the parts using a professional 3D printing/Powder Bed Fusion process with composite polymers fibre reinforced (also known as Selective Laser Sintering) and two materials from the Windform TOP-LINE range: • The polyamide-based composite material Windform XT 2.0 Carbon fibre reinforced for the wipers’ starter motor cover. This component mainly has an aesthetic purpose, but was also able to contain/support the oscillatory movement of the motor. • The polyamide- based composite material Windform LX 3.0 Glass fibre reinforced for the washer reservoir flap valve. This component was mainly functional, just partly aesthetic.
THE RESULT The wiper’s starter motor cover is a
rectangular part manufactured in Windform XT 2.0 material, and features an area for the placement of the wiper arm and a smaller one for the water hose. Considering its position next to the motor, this has to: guarantee electromagnetic compatibility, resist the oscillating movement of the wiper arm and blade, withstand the continuous stress and vibrations caused by the traffic circulation on roads, and protect the electrical unit from external agents. The part therefore needed to be made of a material that would provide stiffness and strength combined with a light weight, ensuring the creation of an accurate, reliable and durable application. Windform XT 2.0, one of the top-of-the-range materials from the Windform TOP-LINE, known for its mechanical properties and representing the ideal choice for functional applications, was therefore chosen by the company. The washer reservoir flap valve was
created in Windform LX 3.0 and consists of a rectangular structure frame and the flap valve equipped with magnets to access the wipers washer reservoir. Its main purpose is to ensure quick access to the wiper’s washer reservoir positioned behind, to protect it from external agents and to resist the continuous stress and vibrations caused by the traffic circulation on roads. Furthermore, it also had to be accurate in detail. It therefore needed to be manufactured in a material that guaranteed reliability, good resistance and aesthetic return. So, Windform LX 3.0 was chosen for its excellent properties and the wide spectrum of use. After manufacturing the parts, CRP
Technology carried out the final tests and delivery. The parts were then installed on Olli without any mounting or fixing issues.
CRP Technology
crptechnology.com
windform.com
MARCH 2022 DESIGN SOLUTIONS 49
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