Purpose of the paper
The purpose of this paper is to review an article on a new type of bicycle, the nylon bicycle, and the technology involved. The paper is based on an article titled “Airbike nylon bicycle –First look” published in bikeradar.com on March 15, 2011.
Summary of the article
Two Bristol-based development engineers, Chris Turner and Andy Hawkins, have released a bicycle prototype made of nylon using a new manufacturing process, Additive Layer Manufacturing (ALM). The bicycle built entirely of nylon at the Aerospace Innovation Centre by the European Aeronautic Defense and Space Company (EADS), named the Airbike, is touted to be an alternative to conventional steel manufactured bicycles. The Airbike consists six distinctly printed pieces that include moving parts in its wheels. The manufacturing company announced that its decision to develop the nylon bike was based on the product’s immediate recognition and wide popularity. A spokesman of the company further clarified that the unusual shape of the bicycle was meant to show the potential of the ALM technology in addition to producing such a high spec, high quality bike. However, a more practical version of the bicycle is set to be produced in the near future and would contain such improvements as refined geometry for better handling and a double-sided chain drive for addressing the flex present in the first prototype. This is expected within a decade.
ALM in manufacturing industry
The ALM technology is predicted to revolutionize manufacturing in the 21st century considering that it is applicable to a variety of materials is relatively faster and more efficient compared conventional manufacturing methods. The ALM technology is a leaner and greener technology that utilizes relatively less material to produce parts that are lighter, more complex and stronger. The ALM technology is therefore used in five main processes in the manufacture of the nylon bicycle. In the formation stage, the shape and size of the bicycle was determined before being ‘grown’ from a high strength nylon powder. The separation phase entailed reduction or shedding off the weight of the object to a desirable lighter product.
The fabrication phase involved joining or fastening of materials together where such parts as wheels, axle, and bearings were integrated within the ‘growth process’ and built in simultaneously. There is possibility to swap damaged parts with other printed replacement parts. The conditioning phase involved changing the internal and external properties of the materials. EADS used it revolutionary technology to manipulate metals, nylon, as well as nylon-reinforced plastics in the molecular level so as to withstand high stress and safety critical biking uses. The last stage, finishing, entailed improving the outward appearance or protecting the surface of the part. The laser is used to draw any desired final shape and incorporation of unique design features such as integrated bearings cased with the hubs or an auxetic structure to offer saddle cushioning.
A variety of uses
The Additive Layer Manufacturing, a type of 3D laser printing, involves a computer-aided design program that guides a laser to fuse together a number of finely powdered metal/nylon/plastic layers. The laser then melts the powder and solidifies it according to a selected pattern. More powder is added which is melted and solidified, adding layer that is only one-tenth millimeter thick unto another layer until a lightweight bicycle is completely formed. The resulting nylon bicycle is 65 percent lighter relative to traditionally manufactured bicycles, yet retains the same strength or steel or aluminum. Compared to traditional manufacturing process, ALM technology uses almost a tenth of materials and reduces waste.
ALM technology can be used in a several other sectors, ranging from the aviation sector to motor industry to engineering to consumers goods to manufacture of parts with moving segments, eliminating the need for assembly, and fusion of different materials in a single part including metals like titanium. The revolutionary manufacturing technology also provides potential for production of products more quickly and cheaply using ‘printers’ from the comfort of people’s offices, shops, or houses. Logistics on military and relief operations would also largely benefit from the capability to produce replacement components in remote regions. At the same, the processes promise to substantially reduced the costs of manufacturing, and consequently, reverse the present trends of urbanization.
Conclusion
The application of the technology in many industries enable integration of strength and weight as it can work with a wide variety of materials, including metals, plastics or composites. It is estimated that every 1kg reduction in weight would result in saved $3500 worth of fuel for a entire lifespan of an aircraft, with similar reductions in CO2 emissions. As such, the increased adoption of the ALM technology would both enable production of products that are beyond the potential of traditional manufacturing processes while helping the manufacturing sector in reducing its waste and carbon footprint. Finally, the nylon bicycle is a type of technological innovation with the potential to provide UK business with a considerable manufacturing edge in the future in addition to stirring economic growth both locally and internationally.
Reference:
Peace, R. (2011). Airbike nylon bicycle – First look. Retrieved from: http://www.bikeradar.com/news/article/airbike-nylon-bicycle-first-look-29615/
