Kawasaki Puccetti Racing takes pole position using 3D printing and scanning technology

The Kawasaki Puccetti Racing team has built-in 3D scanning and 3D printing into its working day-to-working day workflows, revealing that it utilized additive production to earn Round 5 of the Environment Superbike Championship in Italy in 2019.

Particularly, the group employed a RangeVision 3D scanner to scan its Kawasaki racing motorcycle and optimized the fairing of the 3D design applying aerodynamic modeling algorithms. The revamped fairing was made making use of a 3D printed mold and installed on the bicycle prior to the race.

Inside screening confirmed that the lightweight carbon fiber composite fairing elevated the velocity of the bike by up to 4km/hour. The team’s driver also seen the pace improvement, especially on the straight operates of the keep track of.

The carbon fiber fairing was produced using a 3D printed mold. Photo via Kawasaki Puccetti Racing.
The carbon fiber fairing was created making use of a 3D printed mold. Picture by means of Kawasaki Puccetti Racing.

A have to have for pace

In the earth of motorsports, there are a whole host of factors that have an impact on pace. These consist of the electricity of the engine, the pounds of the bike, and the aerodynamics of the physique. As a consequence, racing groups spot a main aim on aerodynamic modeling and testing, which enable the geometry of the motor vehicle to be optimized to give that a great deal-necessary edge.

Even so, regular manufacturing technologies usually struggle with advanced and free-sort shapes, which is in which the structure liberty presented by additive manufacturing comes in significantly handy. Coupled with 3D scanning, 3D printing can be wonderful in scenarios in which lightweighting and optimized drag profiles are a precedence.

The bike was scanned using a RangeVision 3D scanner. Photo via Kawasaki Puccetti Racing.
The bike was scanned applying a RangeVision 3D scanner. Photograph through Kawasaki Puccetti Racing.

Integrating 3D scanning and 3D printing into the mix

In preparing for the Globe Superbike Championship, Kawasaki Puccetti enlisted the support of Russia-dependent carbon fiber specialist UMATEX Rosatom.

To start off off, the organization scanned the total bicycle applying a RangeVision Spectrum 3D scanner. The scanner is characterised by its tiny measurement and portability, which was particularly essential looking at UMATEX experienced to send its specialists around from Russia to Italy. This 3D scanning workflow originally involved spraying the motorcycle with a unique matte spray and masking it in tracking dots to provide as markers for the scanner.

The bike was then digitized with two distinct styles – just one with the fairing and one devoid of. This was finished so UMATEX could properly design the condition of the underlying mounting points to make sure the new fairing would be a fantastic suit. Aerodynamic modeling algorithms have been then utilised to product an optimized fairing geometry: 1 that would allow for for even better speeds.

Ultimately, it came time to build the new fairing. Kawasaki Puccetti turned to Russia-centered 3D printer company PICASO 3D, which used its personal FormaX materials to 3D print the fairing molds. Carbon fiber levels made by UMATEX were then laid out in the forms, heated, and filled with a reinforcing content to develop the last fairing. As nicely as fitting like a glove, the new fairing was lighter and a lot more sturdy than the first element, major the Kawasaki Puccetti Racing team to complete 1st in each of its races.

The Kawasaki motorcycle with its carbon fiber fairing. Photo via Kawasaki Puccetti Racing.
The Kawasaki motorcycle with its carbon fiber fairing. Image by way of Kawasaki Puccetti Racing.

The automotive and motorsport sectors have been prime adopters of 3D printing in excess of the previous several several years. Earlier this year, NASCAR workforce Stewart-Haas Racing turned to 3D printing to generate conclude-use brake pedals 32% lighter than their regular counterparts. Working with Autodesk, the workforce managed to use Fusion 360 generative layout software program to strengthen the rigidity and over-all basic safety of the parts as well.

In other places, British isles-dependent hypercar maker Arash Motor Enterprise also declared the use of 3D printing engineering for the production of conclude-use automotive elements. Utilizing printers produced by Stratasys subsidiary MakerBot, the firm 3D printed a number of structural components that would be place under load, together with bracketry, fasting points, and correcting factors.

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Featured impression shows the Kawasaki bike with its carbon fiber fairing. Picture by way of Kawasaki Puccetti Racing.

Ellen C. McGowan

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