HP 3D printing solution in motorcycle racing

HP 3D printing has found its way into racing. Prototypes of workpieces are usually produced to test their functionality. The Bolliger team goes one step further and installs productive parts for racing.
Team Bolliger Switzerland is one of the few amateur racing teams in the endurance class. Long-distance races place high demands on both man and machine. The factory Ninja ZX-10R (998cc) from Kawasaki is completely rebuilt for racing, except for the frame and engine. Innovative solutions and technologies are sought, and HP 3D printed parts are used.

In collaboration with INNOfactory3D GmbH, a 1:1 tank model was printed on an HP MJF 4200 3D printer, which was used to optimize the chassis and the driver’s position. This led to the development of custom headlight mounts.
The brackets had to align the headlights precisely with the new chassis while still being flexible, stable, and lightweight. The 3-5 mm thick angle construction made of PA12 is firmly fused at the core using HP’s Multi Jet Fusion process and offers the best conditions. To get through the season, small series of 12 pieces are being printed. After the two 24-hour races at Le Mans and Spa, we can proudly say that the first brackets will still be used in the upcoming race at Suzuka. The design and material have so far withstood extreme loads of up to 5G and speeds of up to 350 km/h. These examples show how versatile 3D printing can be.

We wish Team Bolliger continued success and a safe race.

Links:

Team Bolliger #8
SGSolutions
INNOfactory3D