In the second feature of our Fettlers series that looks at some of the most incredible home-made bikes, the focus turns to carbon and specifically the process used by one bike builder to make his own carbon fibre-based mountain bike frames and components.
Adrian Smith uses 3D Printing technology to manufacture the moulds for his CAD-based designs, and then uses carbon fibre fabric to lay over the moulds and produce the final part.
The costs of 3D Printers have come down in recent years and are no longer the preserve of big businesses. In Smith's case, he built his own 3D Printer up from scratch at relatively low cost. Since then he hasn't looked back and has built several inexpensive XC and Downhill bikes under his Carbon Wasp brand name in his home garage in Leeds.
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MENTIONS: @redbullbike @MTBcut
Seriously props to you Mr.Smith...crazy cool! Nice looking rides as well.
Very interesting. I normally print my plugs, finish them off with some dolphin glaze, then duratec surfacing primer and sand to a gloss finish. Then I make a gelcoat mold of that part.
He certainly must be printing in PLA though. Just looked up the melting temperature of PLA and it melts at 302°F, very close to the required minimum temperature for (most) prepregs of 270°F.
I would be very interested to see the surface of the molds he is printing. From experience, I find it impossible (for my skills) to get a mirror like finish on the part.
I have been messing with composites for the past 15 years, so I find this "garage engineering" amazing.
As for those commenting on a longer video, I am certain a 3 hour documentary could easily be created on all the processes and number of hours he has put into developing this. Saying that, there is no way I would give away that knowledge without some sort of compensation. Perhaps we can fund a Kickstarter to pay him to do a full documentary? I know I would watch is several times.
Another HUGE issue I just noticed is he is using a 2x2 twill weave, which is definitely nothing I would use for a structural application. He could be adding that for the surface to make it "look pretty", then adding some unidirectional for the inner layers, but then you are just wasting material and adding weight for no good reason.
It is cool what he has done from a hobbyist standpoint, but this would drive a composites engineer crazy (most likely). I am a hobbyist, so I could be wrong, but if anyone is interested in chatting with people from the newb hobbyist all the way to composites engineers, check out www.compositescentral.com
You will never go back.
Quebec got the commencal model, there are a couple more there too and components..
"3d content central" is another
On phone so do have links
source: I've been making HPVs with carbon fibre for two years
I doth my hat to you deal sir.
@sashamtbrider Because they are made of several layers (FDM) or made of tiny material particles melt together (SLM), 3D printed parts are still more brittle than traditional parts. Maybe we can imagine affordable bike frame made with this technology in the far away future but 3D printers will never bet the ratio weight/strenght of a classic carbon process with molds IMO.
First of all the mold would just melt away in an real autoclave when they material gets cured. (Or cooked how they say in France which is a very charming way to describe this! love it )
The tolerances would not be good enough because the mold would flex way too much in production process. Stuff like position of axle or pivot positions would be all over the place.
The surface or the mold is too rough so the frame coming out would need too much finishing work which would cause the product to be even more expensive.
The production process in this type of mold is to labor intensive as he builds half of every part in a vacuum-bag (like some professional bike builders did in the early nineties) of every part and than combines them which also is not the strongest or lightest way to do this.
So for Adrian that not a big deal because he likes siting down and "carfully" building one bike at a tome, making sure everything is in place and cporrect. He takes his time at sanding and finishing. In between the production steps he just goes over to kitchen for a cup of tee.
He can do this because he is building his babes. He's an artist with carbon and what he is doing is awesome i have to say but for a company that has to earn money this would not be an option...
ABS plastic is a material that bonds under heat and pressure. It's still not cutting it.
Carbon will never be strong enough for commercial use.
Nanotech is sci-fi.
Internet will never replace print media.
3D printing has significant limitations based on what we know today. But we learn so much so fast I believe there is a lot of potential for the technology as it continues to mature and innovative minds join the industry.
Of course we're not going to print precision Boeing engine parts tomorrow - likely never - but it's totally naive to think this tech is not going to affect the tool and die industry.
Also internet did not replace print media. Ther is still a lot of thinks you can onlty do with newspapers... or do you use your iphone when you run out of toilet paper? *lol*
@sashamtbrider They could print with some sort of "discountinous" carbon fiber reincforce plastic with current 3-d printing techniques. These are not quite as strong and high performance as the "continous" reinfocment of uni-directional carbon fiber. Perhaps they could figure something out though.
like you said the reason they are expensive is not because its "new" technology but because it is slow technology. Much like any other production method that requires use of Machines the price of parts, no matter if you do molds or actual parts used in a product, the part price is determined by machine hours much like in CNC machining for example. the longer its on the machine the more expensive.
The really exciting thing about this is that if a technology like that is used to create a product there is no reason to do this in china as Machine-hours cost pretty much the same in China or US/Europe so the development of these technologies and wider availability will be positive for domestic production and might lead to some start-up component companies.
The 3d printer is a one off machine. How is that cheap?
3d printers on the market can not do a whole frame.
You could do the same thing with a carved styra foam.
I would be interested which settings he is running, which material,................... . . .?
Printing Titanium could be the real shizzle IMHO
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