FEATURE
A NEW WAY TO MANUFACTURE I
Additive Fusion Technology combines the benefits of printing, automated tape laying, and compression moulding, Daniel Blackham speaks to Yannick Willemin of 9T Labs to learn more
nnovation in the manufacturing process of frames and components is a constant journey in the cycling industry.
The pros and cons of steel, aluminium, carbon and titanium is a well-thrashed debate.
In recent years, the emergence of 3D printing has seen dozens of high-profile brands dabble with additive-based manufacturing. This has resulted in 3D printed saddles, handlebars,
stems, cockpits, cranks, all the way to entire bikes like the Pinarello Bolide F HR 3D used by Filippo Ganna to break the UCI One Hour Record in October 2022. Since 2018, Swiss company 9T Labs has been pioneering Additive Fusion Technology. “We are developing a new design and manufacturing standard allowing our customers to produce serial parts stronger, lighter, using significantly less resources,” explained Yannick Willemin, director of business development at 9T Labs. “We currently have 60 employees located in Zürich, Switzerland, and Boston, USA. “Currently, we are backed by investors, including Stratasys and Solvay. We have received CHF 25 million so far (approximately £22.5 million).”
www.bikebiz.com The process
9T Labs’ process optimises the layup for a given application, both in terms of performance and build efficiency, and starts with a desired geometry and loading requirements.
The Swiss company then uses its own software, called
Fibrify, to analyse the model. Using finite element analysis, Fibrify works out the areas most susceptible to stress in a real-world environment. Once determined, the design can then be optimised for strength and manufacturing. Following this, 9T Labs’ Build Module uses the optimised design to create a preform with structural continuous fibers being placed precisely. Material is set through two guides that place fiber- reinforced composite tape next to thermoplastic-only tape. Laying the material in this way leads to a product that is strongest where it needs to be and nowhere else, improving material efficiency and limiting build time. In areas where the peak load is lower, the preform is filled with plastic alone or plastic reinforced with short fibers. Finally, the product is finished in the Fusion Module, which compression moulds the final shape of the part. The printed preforms are flat, but can be reshaped in
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