Ceramicspeed partners with dti to create innovative cycling part using slm solutions metal am
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CeramicSpeed companions with DTI to create revolutionary biking half utilizing SLM Options metallic AM

CeramicSpeed, a provider of ceramic bearings for biking and industrial purposes based mostly in Denmark, has partnered with the Danish Technological Institute (DTI), an impartial not-for-profit R&D establishment headquartered in Taastrup, to develop a pulley wheel for skilled cyclists utilizing 3D printing. 

Leveraging its SLM 500 metallic additive manufacturing system from German metallic 3D printer producer SLM options, DTI helped CeramicSpeed manufacture a light-weight and sturdy pulley wheel, or gear wheel, for bettering biking efficiency. The merchandise was developed by the companions in an effort to create new and revolutionary biking know-how for skilled riders to make use of in race-condition testing for this yr’s Tour de France. 

“3D printing know-how has given us a variety of leeway to experiment creatively with design, whereas on the similar time having the ability to optimize a product’s perform,” Carsten Ebbesen, R&D Supervisor at CeramicSpeed acknowledged. 

“The collaboration with DTI has led us to develop and produce gears in a radically new design type that’s solely doable with 3D printing.”

The 3D printed pulley wheels on the Issue Reproduction Comp Winner. Picture by way of SLM Options.

3D printing innovation in biking 

DTI is a analysis establishment that goals to make the most of the newest information and know-how to create new or higher merchandise, supplies, processes, strategies or organizational modes for Danish corporations. It additionally engages in improvement initiatives with analysis and academic establishments each in Denmark and overseas. The institute presents consultancy and providers inside a variety of enterprise areas equivalent to constructing and building to chemistry and biotechnology. 

Examples of its 3D printing R&D initiatives consists of its collaboration with the Royal Danish Academy of Superb Arts Colleges of Structure, Design and Conservation to develop a brand new strategy to 3D printing in building. In April 2019, DTI was additionally granted €10.6 million to arrange an Open Innovation Check Mattress (OITB) specializing in advancing the sphere of 3D printed electronics.

DTI is provided with the quad-laser SLM 500 and twin SLM 280 methods from SLM Options, and has been utilizing selective laser melting for just a few years now. Its expertise in metallic additive manufacturing made the institute an acceptable associate for CeramicSpeed to assist 3D print a pulley wheel with optimized weight and efficiency. CeramicSpeed sought to create the half because it sees the upcoming Tour de France as a testing floor for distinctive biking engineering challenges equivalent to weight optimization. The corporate considers product innovation as the important thing for staying on the forefront of the worldwide cycle trade. 

The 3D printed pulley wheels. Photo via SLM Solutions.The 3D printed pulley wheels. Picture by way of SLM Options.

Advanced and light-weight metallic AM from SLM Options

The pulleys had been printed in titanium on DTI’s SLM 500 metallic 3D printer. SLM Options’ additive manufacturing know-how helped to offer the complicated geometry required for the half, which incorporates 17 spokes, a diameter of two mm and a wall thickness of zero.four mm, establishing a hole design within the course of. This assisted in decreasing the entire weight to eight.four grams, an accomplishment that might in any other case be unachievable with out 3D printing, in accordance with Thor Bramsen, Industrialization Supervisor on the Danish Technological Institute:  “The hole geometry of the objects can’t be produced with standard strategies, and the 3D printing together with subsequent specialised processes results in a novel revolutionary product.”

The titanium pulley wheel underwent rigorous testing from CeramicSpeed’s R&D division in an effort to show its high quality, as they’re positioned on the outer gears within the gearshift and are thus topic to put on. Having withstood the take a look at, the gears proved to be extra sturdy and appropriate for corrosion resistance than conventional aluminum components, and likewise confirmed increased power at a decrease density. 

CeramicSpeed additionally wished to enter serial manufacturing of the additively manufactured pulley wheel with out sacrificing high quality. DTI was in a position to optimize CeramicSpeed’s product design for collection manufacturing whereas retaining the complicated geometry and construct high quality. Leaving the design unchanged, DTI added materials for surfaces that wanted CNC machining, which optimized assist, and minimized wall thickness and weight. The institute additionally oversaw the vital post-processing levels to make sure the standard of the pulley wheel when delivered. 

The 3D printed pulley wheels. Photo via SLM Solutions.The 3D printed pulley wheels. Picture by way of SLM Options.

3D printing in biking

CeramicSpeed just isn’t alone in chasing biking innovation utilizing 3D printing applied sciences. Just lately, Californian Digital Gentle Synthesis firm Carbon signed a 3D printed product partnership with main U.S. bicycle producer Specialised to fabricate a motorbike saddle for improved consolation.

In March 2019, Athletics 3D, a French producer of personalized sports activities tools, revealed that it 3D printed customized bike handles that present a greater grip for tetraplegic athlete, Florian Jouanny, who suffers from paralysis. The improved handles will probably be used in the course of the Paralympic World Cup in Emmen, the Netherlands, this September. 

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Featured picture reveals the 3D printed pulley wheels. Picture by way of SLM Options.

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