EDM Additive manufacturing
angle which eliminated overhangs and allowed them to create a geometry that didn’t require internal supports. Metal additive manufacturing provided the design freedom needed to make complex geometries that would not have been possible using traditional subtractive methods, while enabling the lightweighting of components. This included internal lattice structures to reduce weight, an important factor with bike design and manufacture. Once the design and support strategy was optimised, Renishaw began to print the components in aerospace-grade 6AI/4V titanium in 30 micron layers, then heat treated and post- processed them so they can be sent for Finite Element Analysis (FEA). The parts are produced on Renishaw’s flagship RenAM 500Q system, which features an industry leading gas flow system, precision dynamic control and software for connected digital workflows. For performance, keeping the weight of the bike as low as possible is important. Using AM, as opposed to more traditional frame-building approaches, meant we could remove materials from certain areas of the frame where it is not needed, helping to reduce weight from the bike. As a result, the J.Laverack Aston Martin .1R starts from just 7.5 kg.
The .1R is the world’s first ‘boltless’ bicycle, with no visible bolts, screws or attachments at the headset, seat clamp, calipers or bottle cage. Brake hoses are concealed within the handlebars which is a complex part that uses the same design and manufacturing technique applied to the front splitter of a Formula One car. Each bike takes over 1,000 hours to create, including over 500 hours of CNC machine time. Every detail is meticulously engineered and designed to meet the specific needs of each individual. The titanium lugs have an exceptional strength-to-weight ratio due to the internal lattice structures, which enhance stiffness and torsional stability. “This bespoke titanium and carbon bike is a great example of collaboration between British companies that are committed to innovation,” said Chay Allen, Customer Applications Manager at Renishaw. “I think we’ve made the most beautifully designed and engineered bike in the world,” said Oliver Laverack. “It is sleek, stiff, fast, and we have the ability to make them totally bespoke to the individual. It really is a masterpiece in British engineering, and shows what a true collaboration can achieve.” n www.renishaw.com
46 Machinery & Manufacturing
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