Industrial design of a motorbike component
Preliminary issues
One of the services we offer at Enginhum is the industrial design service, at any point in the development of the project. In this case, the project was started, but the part had become complex in design and manufacture, so a specific redesign was necessary. In addition, help was also requested for the manufacture, both in terms of material and recommendations for a better result.
In this case, the aim was to design and manufacture by 3D printing the air outlets of the cooling system of the batteries of an electric motorbike. These are two independent parts and both had to be redesigned to be manufactured using 3D printing.
In order to be able to carry out this project, we started with two designs already made, one for each of the parts. Apart from these parts, we also had a simulation of the forces and vibrations that the part would undergo once installed. In this way, it is possible to analyse the best area in which to make the cuts. In this way, critical areas are avoided, so that the cut can be designed to avoid possible problems once the part has been manufactured.
Thermal analysis of the air flow that must pass through these parts is also available, so in addition to avoiding the most critical part mechanically speaking, the most critical area in terms of air flow and air temperature is also avoided.
Design and development
As a solution to this challenge, the parts are split in half, thus avoiding the most critical areas in terms of mechanical and thermal stress. To avoid disturbance of the air flow, external connections are designed to the air flow. These connections are based on mechanical screw connections with nuts. In addition, a sealing and insulating liquid is applied to completely seal the joint.
These parts are manufactured by 3D printing, using a technical material with carbon fibre filler. In this way, being a motorcycling part, a low weight and fully functional part is achieved, taking into account the physical, mechanical and thermal restrictions.