Electric superbike manufactured by 3D printing

Paul Boughton

The first Italian electric motorcycle Energica Ego has been created using 3D printing.

Manufacturer CRP Group used selective laser sintering technology and polyamide-based materials reinforced with carbon fibres, called Windform, have been used in the construction of the electric superbike. 

The laser selectively fuses powdered material by scanning cross-sections, generated from a 3D digital file’s description of the part, on to the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one indexed layer thickness, then a new layer of material is applied on top, and the process is repeated until the part is completed. Thanks to this technology it is possible to create fairings, headlight covers and motorcycle components apart from the mechanical and electrical parts.

In a short time, 3D printing and Windform materials can lead to the production of prototypes and functional parts, that once made, can be metallised and painted. With free-form design, short fabrication time and the ability to build extremely complex geometry that cannot be easily tooled (or impossible to tool) a customised production is realised that goes beyond the aesthetic model.

Thanks to the Windform line, this allows for the creation of highly-functional and beautifully finished parts suitable for multiple applications.

CRP Additive Manufacturing materials have given birth to global products that create superior mechanical and aesthetic properties.

3D Printing then becomes production manufacturing when applied with materials like Windform that have this high quality and strength.

The CRP Group continues to hold the highest standards of quality thanks this innovation, as well as to a dedicated team who apply their talents from basic material research, to the improvement and development of new machine technologies.

Energica Ego is the first Italian electric motorcycle that recalls traditional endothermal motorcycles that can reach 240km/h and can ride up to 150km. The batteries charge in less than three hours with AC and a half an hour with DC. Energica Ego is also equipped with a KERS braking system that allows it to recover useful energy for use by the motorcycle like F1 cars. Several patents have been registered for this project which is unique in its class.

Windform materials are resistant to water, oils and stress, they differ from other materials,  in their mechanical properties and high quality of the CRP Group.
Energica Ego will be available for purchase in 2015 with ABS and it will be manufactured with traditional productive technologies. The 3D-printed parts made of Windform, such as the fairing will be built with the suitable technologies of mass production. All metal parts such as the engine frame, the forks and the battery pack will be built with casted aluminium.

Finally, the CRP Group will bring to the market a version of the Energica Ego without fairing. This model is built with 3D printing and Windform materials. This prototype is in the study and research phase to check the design, the aerodynamic and the specifications, and will make its debut soon. 

For more information, visit www.crp.eu

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