Some months ago we talked about how David from Bottpower was working again on his Morlaco project, a motorbike with an alternative front end, handcrafted in Valencia with very advanced technology. Today we will gauge the project to see how it has advanced. First we traveled to Vitoria to visit Fernando from Optimus 3D They produce parts with additive manufacturing, which were impossible to imagine some years ago. They also produce some of the Morlaco’s components, so let’s see it. Fernando, let us know who you are and what is your role here in Optimus 3D, and what is Optimus 3D. Optimus 3D is a company specialized in industrial additive manufacturing and engineering services This means that we do not sell 3D printers nor 3D printing materials instead, we provide solutions to our customers based on our knowledge with more than five years working in an exclusive way with these technologies and in the diverse technologies that we have, all of them are industrial, I mean, we do not work, except in some training courses, with desktop machines We work with industrial machines as you will see right now These machines require quite big resources and investment How did start the relationship with David, and with Bottpower? Well, Bottpower, as you well know, is a company very motivated about innovation. They always want to work with the latest technology in every aspect of motorcycles Since several years ago we are doing small jobs with them, quotations and some fabrications both in metal and polymers When the Morlaco project started, Which is a project that was in stand by, and they wanted to start working on it again to show it in a show in Italy in November we didn’t start with the design of parts that can can be 3D printed later on in metal and other parts that we are also doing with polymers like polyamide 12, with technology Multijet Fusion. So we started building a new bike which is a one-off which is going to be an innovation project, it is not going to be a project for mass production Could you show us your company? We are very curious about seeing your machines. Of course. Let’s go! We are a company specialized in additive fabrication as I said earlier, and we have acquired the technologies that we consider that are closer to the final product. We do prototyping, but we are always thinking about the final product For this reason, we need leading technology Regarding polymers, resins, and metals, we have different technologies Resins: we have several ones: polyjet technology, we also have SLA technology, and very soon we will have CLIP technology. Nowadays the resin 99% of the time is only valid for making decorative prototypes that look nice. They are not functional except in a few cases Next is the plastic filament technology, in this case, we have materials with high thermic and mechanical properties and certifications for aeronautic and railway use even in other sectors as food We have other kinds of machines that work with filament and that allow making final product in these sectors But our main interest is in technologies that are going to, guarantee the mechanical and thermic properties, have also a cost closer to a mass production market To do it we start working with polyamide powder technologies Multijet Fusion Regarding the Multijet Fusion with polyamides we have, in this case, a fabrication unit, another unit, that you can see here, of hyper cooling and which also serves to reutilize the raw material this means that we can reutilize up to 80 or 90% of the raw material without having so much waste This technology allows, through heat layers, to fabricate in a volume of 384 mm of edge all the parts that fit inside, in a period of time of around 12 hours. After that, we have a cooling period which is around one and 3 days, depending on how many parts do we have and which tolerances we want to achieve The faster you cool down, the higher the risk of mechanical deformations So, we can talk around two to five days for the fabrication time with this technology The advantage of this technology is that we have no porosity this the additive fabrication technology with is closer to an injected part this is also the additive fabrication technology which allows working with polymers with a fluid, without doing any post-process This technology also permits having costs similar to those of the conventional technology The cost is not the same as an injected part, but it is closer than other additive technologies We are not in the metallic fabrication installation with SLM technology SLM is one of the existing additive technologies in metal We must start to understand that additive fabrication is not that filament machine that everyone has worked with nowadays Instead, it is a group of technologies each one with a different scientific basis, and with different results and benefits we try to group all our knowledge about technologies and additive engineering, to give a specific solution to each customer Talking about metal, we work with SLM, which is the technology that we find it is closer to the final product especially for the automotive, aeronautic and mold sectors We have a cutting edge Renishaw machine It is a very powerful machine that allows new things as working with more than one laser This equipment has a set of characteristics that allow guaranteeing the quality of the final product for sectors as important as aeronautic the impression parameters that are very easy to control On the contrary, it has some requirements … it is not only the machine, but it is also the room conditioning the room temperature and humidity must be under control with a register in our management system we have safety systems that detect any oxygen problem that we could have due to use argon to create an inert atmosphere for the powder and we also need safety systems to avoid fires or explosions with the metallic powder And also, as it happens with any welding product because the SLM is just a laser welding we need an oven to stress relieve especially with some materials as titanium. After that, we take the parts and we remove them from the plate we cut them and once they are cut by wire or by saw, we must remove all the supports, which allow the part is printed during the process, in the machine After, they are not necessary anymore and we must remove them After those processes, the part is finished and, except in some times that the customer is asking for some additional process as milling, polished, painting etc, etc… the part is considered finished This is one of the parts that we are fabricating for Bottpower and as you can see, here we are in the final phase the part has been fabricated in powder polyamide technology the part has been cleaned in the blasting machines which are specific for this use the part now is prepared for its measurement, final control, and shipment this is what we do in this working place We have seen here a lot of machines… I guess that they are very expensive, no? Well, cheap or expensive is always something relative. But in reality, it requires a big investment, it is not something that can be done by an individual and it is not an investment that can be made by any small company We make this big investment to avoid our customers (except those ones who have a very high demand) to make it themselves The investment for an additive metallic fabrication installation in SLM is around 1 million euros, the machine plus the post-processes, plus the installation And the Multijet Fusion that works with powder polymers is around 350000 or 400000 euros If we go one step below, what about the filament Stratasys machine is it more affordable?
It is more affordable compared with the other ones but it is still a very high investment for an individual we are talking around 140000 or 150000 euros then we must add the yearly maintenance contracts, the consumables, spare parts, also, power consumption, for example, the electric oven that we have for stresses relieve of metallic parts consumes many kilowatts, so the power invoice is… you could make many pizzas with it, but they would be very expensive Thank you very much for showing us all this, and now we are going to jump to Bottpower to see the new parts This is the video magic Thank you, thank you Hi David, good morning
Good morning How are you?
Very well and you? We come from Vitoria We were in Vitoria a long time ago We were recording just these parts From the last time we were here, I see that the bike has moved forward Yes, mainly the new parts we have are what would be all the “fibers” of the bike when you were here we didn’t have any of it It had almost only the “skeleton”
Yes Explain to me, starting from the front, what you have been doing Well, the first thing, if we start from the front, one of the most “spectacular” parts is the stay bracket 3D printed in titanium for doing the design we did a Topological Optimization First, we made a drawing of the part, with the maximum volume that it could have after, we made an aerodynamic study to calculate the drag loads that the windscreen should withstand due to the air pressure We calculated it at 300 km/h and from that point, we introduced the loads in the Altair’s software We did it with “Inspire” We did the Topological Optimization We got this shape and then we made some calculus with Finite Element Design to check that everything was correct and from that point, we send the final design to Optimus 3D who printed the part in Vitoria with one of their 3D printers This seems super thin, when you touch it seems that it is going to break.
No, no… it is very strong (shaking it)
I wouldn’t shake it like that No problem, you can push it really hard, it is very stiff Now, can you explain “the secret” that you told me 10 minutes ago? Yes, the windscreen… to avoid having to make a custom one we were looking at many bikes looking for some windscreen that could fit with the design idea that we had and finally, we found this one, which is from a Honda scooter, I don’t remember the model right now but it is a small Honda scooter and yes, it fits quite well In theory, this what protects the rider and allows him to ride at high speed without being expulsed from the bike
Yes, the idea was that to have all this transparent to keep visible the stay bracket and all the front end mechanisms Now, we have here a tachometer, which is just a tachometer There is no speedometer, there’s nothing. Yes, it is very racy
Minimalist It is an American brand, We chose it because it is very light we wanted to use something as light as possible, it is made in plastic and it is very light and that’s the reason we chose it A little bit more down we have the parts that we saw, the air intakes That they made in 3D, this was made from several pieces Yes, that’s it And this goes to the airbox Yes, all the parts, just to make everything easier, and cheaper, are printed in several pieces each one
like a puzzle and then the pieces are glued together These ones were divided into 3 pieces, if I remember well and we glued everything then we sand it to cover up the joints and right now it is just painted You told me that, later one, it will be necessary to cover these parts to make them stiffer Mostly, the most important part is the seat/subframe this part, right now, it is just printed in plastic doesn’t have the necessary stiffness to perform its function as a structural component so, our next step will be to cover all these 3D printed parts with carbon fiber then, once that the parts are covered with carbon fiber the parts will fulfill their structural function and then we will be able to test it because we didn’t test it yet Regarding the fuel tank It is an endurance style, with these fuel caps? How did you make it? Regarding the tank, Here we see the outer carcass Inside it has a fuel cell similar to the ones used on race cars it is made with composites, but it is flexible it has been fabricated in the USA by Pyrotect The idea was this one: to use a fuel cell that allows you to fulfill with everything related to safety you know that the tank will be leak-proof, it won’t have cracks, it won’t have pin-holes, if you have a crash it is not going to break and then, just to give it the external shape the cover is 3D printed This part in the tail.. all these parts are very big even if they are made in different pieces, they are very big in order to 3D print them I find it very curious You can not print these parts with your home printer They are big parts, using the HP Polijet system which Optimus 3D has, and both the finish and the dimensional stability is really good, this is what allowed us to split them into pieces and mount them together and find that everything fits So, first, you designed everything in 3D and then you send it to print, once you now that in 3D everything fits then it goes to the bike and everything fits perfectly We followed that process because this bike is a one-off we are not going to build more units then, to use the traditional method which would be… make the design, make a mold, then take parts from the mold it is a long process, it is expensive, and for doing just one unit this is much faster, because as you say, you design it on the computer, you send the file and in four days you have the parts it is much faster You also have the front fender made which is also 3D printed everything is 3D printed! Is there something more that you would like to show us? Well, we have the exhaust, which is Akrapovic. We kept the original collectors, because they are made in titanium, and the changed the original Honda silencer which was much bigger and heavier, and we mounted this one from Akrapovic which is more compact and light
Did Akrapovic have one for this CBR? No, this one is adapted I don’t remember well This is from a Yamaha R1 or from another Honda model but it is from a current model What is left to see it running? Because the next video will be, obviously, you riding it The main thing is what I said about adding some carbon fiber layers That’s the main job Then we must finish the wiring loom and then many small details although apparently you see the bike and it seems finished but there are always many details that all together take a lot of time Is there some paint scheme that you are going to use? We will make a graphic design, but if I tell you the truth, we don’t know yet how it will be but yes, we will make a design, although at the same time we will try to keep the carbon fiber seen Now we arrive at the betting moment. David, when will I see the bike running? In the latest video I told you that it would be at the end of the year and that has already happened Well, we are not so far, if you see it now, it looks like you start it and it runs You must take into account that this is a side project We do it in our free time it is not a main project the most important, every day, is to attend the customers, build the bikes for them, work in new projects to develop new products that we are going to market.
So we work on this project when we have some time and also at an economic level, we do it as we can afford it and this makes that everything advances in a more quiet pace that what we would like but anyway, I think it will take a few months more Summer? Yes Summer
Deal! Summer is a good time to test new bikes! So you know it guys, the next time that we see the Morlaco it will be next summer and we will see it running, David said it, not me. David, thank you very much for allowing us to visit you once again Thank you to you for coming If you liked the video, hit the like button If you are not subscribed, do it.
By the way, do you have a Youtube channel? Yes, we have it. Until now we didn’t make too many videos, but now we are starting to make more. What is your name on YouTube?
Bottpower You know it. Look for Bottpower and today subscribe to them instead of us let’s make it easy for David And if you have any technical question about the bike, ask it in the comments and for sure that David will reply. Bye!