CRP Technology’s R&D department tackled the development of a new front air inlet for a racing customer to solve space issues in the front fork area.
It has been manufactured in Windform materials by using an SLS Additive Manufacturing technique.
Testing had shown that increasing air flow to the air-box improved the performance of the engine at every RPM range. This led the team as well as the engineers to conclude that they need to design a new track ready inlet. This design would make the air inlet longer, and bring the opening up to the front side of the fairing, in order to have a direct air flow with less turbulence.
Among the goals to be achieved, was the need to avoid modifying the existing frame and the existing triple clamps. The design would have to fit to the existing platform in order to test the on-track advantages and disadvantages of using this solution, and to make a direct comparison with the current standard inlet.
Once a first draft of the air inlet was developed, a prototype in Windform GF 2.0 was created.
The first prototype allowed engineers to see if the design fitment was correct and suitable for assembly. It was revealed by the first design that some sections needed to be changed due to the lack of space available under the lower triple clamp. This problem is further complicated when the bike is cornering and under braking conditions.
To optimize the volume of the inlet duct under the lower triple clamp, the engineers adopted a creative approach and decided to use a portion of the duct in Windform RL , the new rubber-like composite material produced by CRP Technology. This would be bonded to the main structure that was made out of Windform XT 2.0 for evaluation in racing conditions. To facilitate this they also carried out a bonding test to study the characteristics of the final assembly.
innovative SLS front air inlet made with Windform materials
Video of innovative SLS front air inlet made with Windform materials
Companies: CRP Technology srl