Working with Bright Laser Technologies (BLT), bicycle manufacturer Titan Super Bond has developed the first fully 3D printed titanium alloy bicycle frame in China and Asia.
Employed by Titan Super Bond, the BLT-A320 machine helps produce high-precision titanium alloy bicycle handlebars and head tubes known for their lightweight, high strength, corrosion resistance, and long service life. This lightweight design contributes to reduced overall vehicle weight, improving speed, while the high-strength titanium alloy frame facilitates efficient power transfer, enhancing maneuverability, and offers exceptional shock absorption capabilities.
Bicycle manufacturing made easier with metal AM
The decision to adopt metal additive manufacturing addresses challenges faced by the Chinese bicycle industry in developing high-end parts, according to the company. With precise control and high-quality machines, metal 3D printing proves instrumental in producing complex structural parts while meeting industry requirements for accuracy (0.03mm). Customization capabilities optimize rider posture and energy output.
Metal 3D printing simplifies and streamlines production compared to traditional processes like precision casting, CNC machining, wire cutting, welding, calibration, and surface treatment. This results in a 30% reduction in production cycles, over 20% savings in materials, increased production efficiency, strengthened welding areas, reduced labor intensity, shorter working hours, and lays the groundwork for future robotic automated welding.
Previous attempts at bicycle manufacturing using metal 3D printing have made news. For example, Sturdy Cycles, a bicycle manufacturer, adopted Headmade Materials‘ Cold Metal Fusion (CMF) technology for producing titanium bike parts. In a previous collaboration, the company worked with RAM3D to 3D print components for its road bikes.
British Cycling approached Renishaw for help in 3D printing aluminum and titanium parts for its track bike that debuted at the Tokyo 2022 Olympic Games. Partnering with Materialise, Canyon, revealed a 3D printed mountain bike prototype for Bike Magazine Germany’s ‘Ride Green’ campaign, demonstrating eco-friendly manufacturing methods.
BLT’s metal AM abilities benefit the broader 3D printing industry
In 2022, Titan Super Bond made significant advancements in its research and development and production abilities in metal 3D printing, due to BLT’s Laser-Powder Bed Fusion (LPBF) metal 3D printing machines’ integration, notably the BLT-A320. This collaboration, with the added support of BLT, played a crucial role in Titan Super Bond’s achievements and notably influenced its position in the high-end bicycle market
By overcoming challenges associated with deformation control of intricate parts and weight reduction, the partnership addressed a considerable obstacle presented by elements with a thin wall thickness of only 0.9mm. Despite the challenge, a comprehensive solution was produced, spanning production procedures, part design, support, and lattice control. This holistic approach ensured the successful completion of the ISO 4210 dynamic fatigue strength test for the 3D printed parts, validating their quality and long-lasting resilience.
Away from bicycle manufacturing, BLT’s metal 3D printing technologies were previously used in the healthcare sector. One such example includes the company’s BLT-A160D metal 3D printer helping develop MicroNeuro, the world’s first flexible robotic system for minimally invasive brain surgery. Created by the Centre of Artificial Intelligence and Robotics at the Hong Kong Institute of Science & Innovation, MicroNeuro integrates various technologies, including multilevel flexible endoscopy, high precision control, augmented reality surgical navigation, and artificial intelligence.
Additionally, Chinese medical firm Wedo Bio-Medical Technology secured market approval in China for its 3D printed spinal implant, WedoCage, utilizing BLT’s BLT-S210 and BLT-S310 metal 3D printing systems. The Hydroxyapatite-Coated Porous Titanium Alloy Interbody Fusion Device received a Class III Medical Device Registration Certificate from the National Medical Products Administration.
What does the future of 3D printing for the next ten years hold?
“Why did the 3D printer go to therapy? Because it had too many layers of unresolved issues!”
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