CeramicSpeed，用于丹麦的骑行和工业应用的陶瓷轴承供应商，已与该公司合作Danish Technological Institute(DTI), an independent not-for-profit R&D institution headquartered in Taastrup, to develop a pulley wheel for professional cyclists using 3D printing.
Leveraging itsSLM 500来自德国金属雷电竞充值3D打印机制造商的金属添加剂制造系统SLM solutions, DTI帮助CeramicSpeed manufacture a lightweight and durable pulley wheel, or gear wheel, for improving cycling performance. The item was developed by the partners in order to create new and innovative cycling technology for professional riders to use in race-condition testing for this year’s Tour de France.
CeramicsPeed的研发经理Carsten Ebbesen说：“ 3D打印技术使我们有很多余地来创造性地进行设计，同时也能够优化产品的功能。”
“与DTI的合作使我们以根本新的设计形式开发和生产齿轮，只有3D打印才有可能。”
3D printing innovation in cycling
DTI is a research institution that aims to utilize the latest knowledge and technology to create new or better products, materials, processes, methods or organizational modes for Danish firms. It also engages in development projects with research and educational institutions both in Denmark and abroad. The institute offers consultancy and services within a wide range of business areas such as building and construction to chemistry and biotechnology.
Examples of its 3D printing R&D projects includes its collaboration with theRoyal Danish Academy of Fine Arts Schools of Architecture, Design and Conservation开发一种新方法3D printing in construction. In April 2019, DTI was also granted €10.6 million to set up an Open Innovation Test Bed (OITB) focusing on advancing the field of3D打印电子产品.
DTI配备了Quad-laser SLM 500和TwinSLM 280systems from SLM Solutions, and has been using selective laser melting for a few years now. Its experience in metal additive manufacturing made the institute a suitable partner for CeramicSpeed to help 3D print a pulley wheel with optimized weight and performance. CeramicSpeed sought to create the part as it sees the upcoming Tour de France as a testing ground for unique cycling engineering challenges such as weight optimization. The company considers product innovation as the key for staying at the forefront of the global cycle industry.
Complex and lightweight metal AM from SLM Solutions
The pulleys were printed in titanium on DTI’s SLM 500 metal 3D printer. SLM Solutions’ additive manufacturing technology helped to provide the complex geometry required for the part, which includes 17 spokes, a diameter of 2 mm and a wall thickness of 0.4 mm, establishing a hollow design in the process. This assisted in reducing the total weight to 8.4 grams, an accomplishment that would otherwise be unachievable without 3D printing, according to Thor Bramsen, Industrialization Manager at the Danish Technological Institute: “The hollow geometry of the objects cannot be produced with conventional methods, and the 3D printing in combination with subsequent specialized processes leads to a unique innovative product.”
The titanium pulley wheel underwent rigorous testing from CeramicSpeed’s R&D department in order to prove its quality, as they are placed on the outer gears in the gearshift and are thus subject to wear. Having withstood the test, the gears proved to be more durable and suitable for corrosion resistance than traditional aluminum parts, and also showed higher strength at a lower density.
CeramicsPeed还希望输入添加性制造的皮带轮的连续生产，而无需牺牲质量。DTI能够优化CeramicsPeed的产品设计，用于串联生产，同时保留复杂的几何形状和建立质量。将设计保持不变，DTI为需要CNC加工的表面添加了材料，从而优化了支撑，并最小化了壁厚和重量。该研究所还监督了重要的后处理阶段，以确保运送时滑轮轮的质量。
3D printing in cycling
CeramicSpeed is not alone in chasing cycling innovation using 3D printing technologies. Recently, Californian Digital Light Synthesis companyCarbonsigned a3D printed product partnershipwith leading U.S. bicycle manufacturer专门制造自行车马鞍，以改善舒适性。
In March 2019,田径3D法国定制运动器材制造商，透露了3D printed custom bike handlesthat provide a better grip for tetraplegic athlete, Florian Jouanny, who suffers from paralysis. The improved handles will be used during the残奥会世界杯今年9月，在荷兰的艾曼（Emmen）。
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Featured image shows the 3D printed pulley wheels. Photo via SLM Solutions.
