E-moto AGH, a team of students from the Polish Academy of Science and Technology, designed and built an electric off-road motorcycle. The students not only managed to prove the benefits of alternative energy sources, they also learned how to apply the latest solutions, such as the Sinterit Lisa Pro desktop SLS 3D printer. For the most part, the motorbike was created in the laboratory of the academy.
“We spend most of our time in the workshop,” says team leader David Senko. “Our project is the creation of electric motorcycles. Two bikes are now ready: with a capacity of eight and thirty kilowatts.”
The E-moto AGH team builds their bikes from scratch. Many parts are made by hand, for example, using vacuum forming or machining. The rest of the parts are 3D printed. Students use several printers, mostly of FDM type. But there was a special task for which the technology of selective laser sintering was employed.
“We needed to print a heatsink housing, and SLS is the best fit for this purpose, because prints are durable and some parameters are more predictable than FDM,” says Jakub Sobański. “It is also very important that we can use a wide range of powders.”
As already mentioned, the E-moto AGH used a Sinterit Lisa Pro desktop SLS 3D printer to make the radiator case. One of the advantages of SLS technology is that it allows printing very complex designs. Students printed parts with a honeycomb structure. The air baffles have been designed to keep the radiator from getting clogged with dirt and gravel.
“The print came out so good and elastic that although the bike fell several times, the part was not damaged,” says Jakub Sobański.
How affordable is SLS 3D printing?
There are two types of SLS 3D printers on the market: industrial and desktop. They differ in the volume of the print chamber, the degree of process automation, and the range of supported materials.
Desktops are great for research, rapid prototyping, and even small-scale production. The huge potential of SLS lies in new materials with individually selected properties, which can include conductivity, heat resistance, water repellency, and so on. Besides, desktop SLS printers are several times cheaper than industrial ones.
AGH students learned how to get the most out of the cutting-edge 3D printing technology and printed functional motorcycle parts on the Sinterit Lisa Pro, with which they took part in the Smart Moto Challenge in Spain.
“The choice of a printer was also related to the choice of printing material. When choosing the Sinterit Lisa Pro 3, we took into account the maximum coolant temperature, which is 60 degrees Celsius. PA12 powder, the main consumable for SLS 3D printers, was a very good fit for our project,” added Jakub Sobański.
SLS 3D printers are ideal for R&D applications. The technology goes far beyond prototyping. The quality and durability of printouts are so good that, under certain conditions, SLS devices can successfully print final products.
Smart Moto Challenge Championship in Barcelona
The E-moto AGH team installed 3D printed radiator housings on their bikes and took them to the Smart Moto Challenge.
The international championship has been held for eight years in a row, inviting student teams from different countries. Each team designs and manufactures its own electric motorcycle.
First, the commission assesses the technical documentation and business plan of each project. Then they check how the motorcycle endures the rain, how the headlights and brakes work, etc. In conclusion, they carry out dynamic tests: acceleration, energy consumption, and the like. Bikes participate in slalom, cross-country, endurance races.
Both motorcycles made by the E-Moto AGH team passed all the tests. Now the students are developing a new version for next year's championship.
Prototyping for the automotive industry requires technologies that guarantee high fidelity and durability. That is why selective laser sintering is the choice of many research groups and manufacturing companies. This reliable technology is now available to small and medium businesses, universities, and schools.
This is especially important for technical universities that train future engineers and inventors. If the workshops of universities have the most high-end tools and machines, students will be able to study and master the newest and most advanced technologies.
Tech specs
OS: Windows
Power input: 220–240V AC, 50/60 Hz, 7A
Dimensions: 690 x 500 x 880 mm
Weight: 90 kg
Software: Sinterit Studio 2018
File formats: STL, OBJ, 3DS, FBX, DAE, 3MF
Camera: yes
Laser: IR 5W
Power consumption: 1,8 kW
Build volume: 150 x 200 x 260 mm
Build chamber temperature: 192 °C
Technology: SLS
Min. layer height: 75 μm
XY accuracy: 50 μm
Printable materials: PA11, PA12 Smooth, Flexa
Display: 7" color touchscreen
Connectivity: Wi-Fi, USB
