KTM chooses Prosilas 3D printing to ride in the wind

KTM chooses Prosilas 3D printing to ride in the wind

Ktm + Prosilas Case History

Passion for speed meets 3D printing innovation

Since the beginnings of 3D printing, one of the sectors that has most perceived and grasped its potential is undoubtedly racing and motorsport. The demand for parts and components with high mechanical performance, but in limited production runs and tight deadlines, make additive manufacturing the ideal choice for those who produce high performance cars and motorbikes.

This is well known by the Austrian company KTM, whose Aerodynamics and Factory Racing departments have persistently researched and developed revolutionary solutions, not only for the production of functional prototypes, but also for end-use components, to be used both in the wind tunnel and on the track.

A partner for 3D printing of carbon-filled nylon elements

It was precisely with a view to creating parts capable of exceptional performance, not only mechanical but also aerodynamic, that the collaboration between KTM and Prosilas was born. In particular, Prosilas’ role is to work alongside the Austrian giant as a partner for the 3D printing and finishing of parts in Polyamide PA2200 added with carbon fibre using SLS technology. A true additive manufacturing process in Nylon with carbon that, thanks to the printing parameters specifically studied by Prosilas technicians for the EOS P770 printer, has also been proposed for large format parts (680x370x540 mm chamber). Prosilas is the only company on the European scene that can offer this kind of 3D printing for objects and components of this size in PA 603 CF  material.

Aerodynamic appendix for the motorbike KTM RC16 MotoGP

Brad Binder, Red Bull KTM, MotoGP RC16 Circuit Ricardo Tormo

From simulations to the wind tunnel: what were KTM’s objectives when you chose Prosilas as your partner?

The desire was to identify and develop additive-moulded materials that could undergo post-processing to bring the surface finish up to the levels required for our aerodynamic needs,” says Daniel Marshall Team Leader Aerodynamics at KTM: “In particular, we needed to improve the correlation between simulations and subsequent testing, and then possibly produce parts that could cope with track tests and even race events. Thanks to the qualities of PA 603 CF and the surface finishes offered by Prosilas, we can now have parts that fully meet our requirements. We have been able to decisively improve the correlation between computational simulation and wind tunnel testing“.

Vanna Menco, CEO Prosilas, Noemi Rossi, Sales Manager Prosilas, Daniel Marshall Team Leader Aerodinamics KTm , Michele Paolinelli Sales Account Prosilas

From right to left: Vanna Menco, CEO Prosilas; Noemi Rossi, Sales Manager Prosilas; Daniel Marshall Team Leader Aerodinamics KTM; Michele Paolinelli Sales Account Prosilas @ KTM Factory Racing 

Brad Binder  & Jack Miller,  motorbike RC16 Red Bull KTM. MotoGP 2023

Constant comparison in the name of optimisation

Highly innovative results, therefore, achieved through an ongoing collaboration between KTM and Prosilas to combine aerodynamic and engineering expertise with that of additive manufacturing: “The choice of materials and surface and post-processing finishes was made in constant collaboration with Prosilas,” explains Daniel Marshall. “Thanks to this partnership, further progress was made in optimising the components in terms of weight, rigidity and waste reduction

What made KTM choose 3D printing over the traditional methods previously used?

“We decided to go for 3D printing for two very specific reasons: short lead times and minimal quantities,” concludes Daniel Marshall: “We usually produce test parts in one-offs, so traditional production processes are not applicable in terms of both cost and delivery time.

Additive technology allows finished parts in production timescales that are unthinkable for any other technology. For example, eight aerodynamic appendages for the tail of the KTM RC16 MotoGP motorbike were printed and finished within just four days of the order being placed. An astonishing result, which only reaffirms the now inseparable link between racing and motorsport and 3D printing.

A story, the one between Prosilas and the historic KTM, that once again confirms Prosilas’ commitment to being a winning ally to industrial production.

Appendice aerodinamica per la moto KTM RC16 MotoGP

Press Release

 

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Armotia Case History

Armotia Case History

Armotia + Prosilas Case History

Prototypes of electric motorcycles: the support of 3d printing.

Prosilas played a key role in the realization of the Armotia project, a company based in Osimo that is dedicated to the design and production of electric motocross and enduro motorcycles. Thanks to the collaboration between these two companies, it was possible to create innovative and high-quality prototypes that represent a true revolution in the world of motorcycling.

 

Armotia: the project

ARMOTIA presents DUE X and DUE R, the first two electric series motorcycles with two electronically controlled distribution drivetrain.

Our motorcycles have exceptional traction characteristics that will give you amazing riding sensations allowing you to experience every type of track, on and off road, as never before.

Besides all this, ARMOTIA offers standard intelligent features and possibilities. Such as an integrated smartphone to record videos, check performance, save telemetry data, and share all your routes. Or the possibility to personalize the most appealing parts of the fairings with a 3D printer, to make the most special motorcycles even more “special” that you have ever seen. Because if it is true that two wheels move the soul, with ARMOTIA you will discover that two-wheel drivetrain definitely does it better.

From the Armotia website.

 

Prosilas’s expertise

Armotia has relied on 3D printing technology for the production of parts and components necessary for the creation of the DUE R and DUE X motorcycle prototypes. In this context, Prosilas has provided valuable support thanks to their expertise in materials and finishes for 3D objects.

Thanks to the consultancy provided by Prosilas, Armotia was able to choose the most suitable materials for the realization of their prototypes, ensuring a high level of resistance and surface finishing: alumide and glass-filled polyamide (PA12 GF) for fairings and shells.

Aluminum is a very resistant material that presents a good surface finish, making it ideal for the realization of parts that require high-quality finishing. Moreover, this material can be easily painted, allowing for further customization of the prototypes.

On the other hand, the glass-filled polyamide is a highly resistant material, which is perfectly suited for the production of parts that require greater robustness, and also CNC treatments.

Thanks to Prosilas’ consultancy, Armotia was able to choose the most suitable material for each specific application.

This synergy shows how 3D printing and the consultancy of specialized companies like Prosilas can make a difference in the realization of innovative and high-quality projects.

 

 

Post-processing treatments: painting

In addition to advice on the optimal choice of materials, we offer advice on which post-process treatment is the most suitable to achieve the best possible result.

The painting service allows to obtain parts in different customizable colors with a surface finish similar to that of the parts produced with injection molding. Our finishing department is able to replace the entire range of RAL colors and special colors according to customer requests.

Painting is an important aspect to consider in the production of parts in 3d and it gives an added value allowing to get an aesthetically appealing prototype and very close to the final product.

Thanks to advanced technologies and materials, the prototypes and series produced in Prosilas can also have matt, glossy and metallic finishes or resistant to UV rays or to hydrocarbon.

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NEW SPARE PARTS AND SPARE PARTS: 3D PRINTING FOR THE HYDRAULIC SECTOR.

NEW SPARE PARTS AND SPARE PARTS: 3D PRINTING FOR THE HYDRAULIC SECTOR.

The opportunities offered by 3D printing are now multiple and the continuous developments of technology allow us to respond promptly even to the needs of sectors that were considered too specific such as hydraulics and hydrothermohydraulics.

An innovative solution

In particular, the innovative combination of industrial 3D scanning and 3D printing with SLS tencology offers a wide range of opportunities. In particular, in the hydro-hydraulic sector, the production of implementation and replacement parts on furniture, taps, sanitary ware, air conditioning and convector systems represent one of the greatest challenges and needs.

It is precisely here that additive manufacturing represents an excellent alternative, with numerous advantages over more traditional technologies, both from the point of view of the aesthetic and mechanical performance guaranteed on the parts produced, both for its ability to reproduce obsolete or discontinued components, intervening if necessary on the optimization of geometries quickly and functionally .

Roberto Nasini Prosilas Stampare 3d per l'industria manifatturiera
la produzione Stampe tre d per produzioni e preserie Prosilas

Rebuilding spare parts that are now out of production or whose mold has been lost has never been so simple and fast!

A process that we at Prosilas know well and that through the use of our 3D scanners and the application of reverse engineering has allowed us to produce a particular model of hydraulic tap breaker and a shower customized to the specific request customer’s.

With the 3D file  from the scanning of the part out of production, the SLS technology used in our laboratories Prosilas allows  to 3D print functional elements, also offering the possibility to work on large results or series (working chamber 680x380x540 mm), being able to choose from a wide range of materials: PA12, PA12+Glass spheres, PA12 + Carbon fiber, PP (Polypropylene). 

An opportunity, that of putting back on the market spare parts out of production getting the reconstruction through additive technology, that not only allows to answer to a specific need without looking for solutions of fortune or sketched, but which makes the production itself much more sustainable and performing. 

On-demand warehouse

 

The case of the 3D reconstruction and printing of the tap and a custom shower model shows how on the one hand 3D printing allows to have a production according to the needs, thanks to a virtual warehouse on demand without the need to manage a physical storage and from the other offers the opportunity to rethink the component in additive, in order to obtain an improvement of the mechanical performances. 

Innovative and customized additive solutions that we propose, supporting companies in all sectors, even those universally recognized as the most demanding just like the world of hydrothermohydraulics. 

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Eos P770 n° 5

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Prosilas for Philipp Plein, the shoe revolution starts from a 3D sole

Prosilas for Philipp Plein, the shoe revolution starts from a 3D sole

Philipp Plein Case History

Prosilas: AM Service & Consulting 

Since the beginning of our entrepreneurial adventure, in 2003, we have chosen not to specialize in a particular production sector, preferring to offer as a service to customers in different sectors. Thus, we have maintained a flexibility that has proved particularly successful when, in our transition from prototyping service to manufacturing ally, we were commissioned the sole of a shoe for one of the brands symbol of fashion luxury: Philipp Plein.

 

R&D on Tpu 

In 2020 we enabled the use of TPU, a rubber material widely used in the moulding of soles, on our SLS production systems.  This gave us the opportunity to start the collaboration with Philipp Plein, with the aim of creating a capsule collection of footwear in which to combine innovation and luxury, dedicated to a specific niche of the brand’s customers.   At the heart of the work, for us, was the creation of an attractive model in line with the taste of the brand and the development of a product that exceeded a series of requirements of strength and durability.

 3D SOLE

In fact, the sole is one of the crucial elements of a shoe and one of the most stressed by the use. We then conducted a detailed study and a deep work on design and process to ensure replicability. For this reason we also supported the company that would then assemble the final shoe, facing and solving together specific processing problems that usually do not concern those who make prototypes.

The result ?

First, we got a sole completely out of the standard of a traditional ones, with a latticed structure; then, the opportunity to innovate the style thanks to the possibilities offered by 3D printing; finally, we opened doors to unique pieces, unthinkable (or infinitely more expensive) when all the process of creation must use injection moulding. 

Thank to a work like this, a progressive set of know-how is created that is completely new but can be used in all subsequent experiments. So, for example, for Philipp Plein shoes, we conducted several tests on the tightness of the colors of the soles, especially white – which should not turn yellow or turn on other shades – and black – which should not shin, so it can not be painted.

How was that possible? 

The problem-solving business approach was essential 

“There are no closed doors,” explains our CEO Vanna Menco, “We always accept challenges, we like to evolve and find solutions”. In this the imprinting of my father was fundamental, because – she continues – he “loves to crack his head on problems” and not by chance he still leads the Research and Development department.

Our transition from suppliers to consulting service  has been made possible by a know-how developed to support the customer at all stages of production, making available our deep expertise in 3D printing. So, we went from consulting at the prototype stage to consulting for all product development, also providing knowledge on specific steps, such as the blend of the material to be used to achieve a certain result. 

Our constant commitment to be the best possible consulting service for AM world. 

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Eos P770 n° 5

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Biocompatible material for 3D printing: Polycaprolactone

Biocompatible material for 3D printing: Polycaprolactone

Case History – Medical

Application in the Medical sector realized through the use of biocompatible and absorbable materials – Polycaprolactone – processed with 3D printing technologies and additive manufacturing SLS – Selective Laser Sintering.

 

Polycaprolactone – PCL: biocompatible material for 3D printing

Our team of experts has perfected a particular formulation of material capable of producing functional parts implantable in the human body.

In this specific case we produced a biocompatible and absorbable material composed of Polycaprolactone and Hydroxyapatite. The chemical composition of the material made possible the realization of a special stent that was implanted in a 5 year old child suffering from bronchcomalacia at the Bambino Gesù Hospital in Rome.

Bronchial stent in 3D printing:  design and implementation

The process of producing the stent was the result of 3 years of research and development that Prosilas has faced pro-bono in order to realize the part in question. The realization was possible through a design phase and a production phase.

The design phase of the geometries was performed on the basis of a computed axial tomography (CT) showing the area to be reproduced. The acquired images were useful to create a new geometry completely customized on the patient.

The case study is the first and only in Europe.

Once the geometry was validated, hundreds of tests on 3D printing (SLS) technologies and materials were performed. The right balance between process parameters and chemical composition of the material led to the creation of the stent. 

Carbonmide drone chassis and 3D printing

Carbonmide drone chassis and 3D printing

Case Study – Topology optimization

New case study developed in Prosilas concerning the production of a chassis for drones produced with SLS technology – Selective Laser Sintering – and Carbonmide material (PA12 + carbon).

 

Drone Chassis

Among the services of Prosilas can be listed, in addition to rapid prototyping, serial production, design and development of new applications with reverse engineering

This case study concerns the optimisation and redesign of a structural element for drones. The production of the component of the new experimental drone was the result of a redesign operation aimed at making the most of the potential of additive technologies.

Topology optimization 

The component has been generated by the topological optimization of geometries previously studied.  This process created a new part with reduced weight which it is  able to guarantee important performance improvements of the drone.

The process parameters specially developed in Prosilas, have made possible a marked improvement in the mechanical performance of molded components. Just think that compared to the materials available on the market, Prosilas technicians have been able to improve the mechanical performance of Carbonmide (Polyamide 12 loaded with carbon fiber) by 50%.

Particolare drone stampa 3d sls carbonmide

Technical benefits

The laboratory tests carried out on the PA12 + carbon tuning in Prosilas with customized process parameters confirm the higher mechanical strength obtainable through our certified SLS additive manufacturing processes.

Thanks to the advanced performance of the material it will be possible to develop new applications that can guarantee greater strength and greater lightness at the same time.

 

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Eos P770 n° 5

Eos P770 n° 5

The fifth Eos P770 3D printer has arrived!  In addition to improving production efficiency, it is...

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