One-piece prototypes validate cycle design

Edited by the Engineeringtalk editorial team Sep 21, 2005

3T RPD produced functional and aesthetically pleasing prototypes to assist Paul Wolfson in his final year of study in Industrial Design and Technology at Loughborough University.

3T RPD has produced functional and aesthetically pleasing prototypes to assist Paul Wolfson in his final year of study in Industrial Design and Technology at Loughborough University.

Wolfson's intention was to challenge traditional bicycle manufacturing techniques and prove that polymeric materials would be suitable to produce a viable product.

"Urban" is a polymer bicycle designed to meet the needs of the inner-city commuter and town cyclist.

Simplistic design and an innovative flatpack polymer frame mean that manufacturing, assembly and transportation costs are all dramatically reduced while creating a highly original product to lure new users to cycling as a means of transport.

Wolfson's decision to use 3T's selective laser sintering (SLS) process was driven by the fact that not only could it produce the components in single pieces, but also that this method of prototyping created an economical, fully functional prototype.

3T has the capacity to produce parts on its EOS P700 laser sintering machines up to a build volume of 700 x 380 x 580mm.

Therefore, single piece parts can be built which reduces the need for joints and post-assembly, hence dramatically increasing their strength and functionality.

Another advantage was that the prototype components could be produced directly from CAD data used extensively during the design process for both development and presentation of the concept, saving a considerable amount of time in creating a final prototype.

The SLS prototype had the necessary physical properties to fully test the concept, and was suitable to undergo further model-making work in order to make it appear as the desired design would.

Wolfson says: "The functionality of SLS prototypes far exceeded my expectations, as I never envisaged that I would actually be able to assemble the bicycle and ride it".

"Prototyped at the intended wall thickness of the production part gave me a realistic representation of my design, without any modifications having to be made".

Once in production, the entire bicycle would be pre-assembled ready for "flatpack" delivery.

The consumer decides what features, finishes and accessories they require, and an order is made directly to the manufacturer.

The product is then shipped straight to the consumer and, with minimal knowledge or expertise, the bicycle is fully assembled and ready to ride.

The tough two-piece glass-reinforced nylon frame joins internally through interlocking ribbing and clamps all other major components together.

Alongside its manufacturing advantages, the polymer frame offers fantastic weather resistance, user-defined customisation and an eye-catching aesthetic appeal.

The Audi Design Foundation sponsored the prototyping phase of Wolfson's project.

The foundation offers a wide range of opportunities for new talent, including events, grants to build prototypes and the prestigious Audi Young Designer of the Year Awards, giving young designers the opportunity to develop their talents, improve their skills and kick-start their design careers.

Criteria for obtaining such a grant states that "good design should challenge existing protocol, use technology as a tool (not a gimmick), show a new direction or methodology and empathise with the potential user".

Since completion of the prototype, the bicycle has been exhibited at several design exhibitions including Loughborough University's annual Industrial Design and Technology Degree Show, New Designers 2005 at the Business Design Centre in London, and it is due to be exhibited at Cycle 2005 at Excel in the Winter of 2005.