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HOW IT'S MADE – A 3D-printed eBike frame made with free motion printing

Arevo, the Silicon Valley company redefining global composites manufacturing through digitalization, announced a partnership with boutique bike manufacturer Franco Bicycles to deliver the world’s first 3D printed, continuous carbon fiber single-piece unibody frame for a new line of eBikes Franco will sell under the “Emery” brand.

Arevo DNA technology is unique in the additive manufacturing (AM) world as it features patented software algorithms enabling generative design techniques, free-motion robotics for “True 3D” construction, and direct energy deposition for virtually void free construction all optimized for anisotropic composite materials.

Further a unibody bike frame construction uniquely enabled by Arevo technology is setting a new benchmark in high-performance bikes. The Arevo frame is made as a single part, in contrast to current composite frames, which are made of many parts glued together. With Arevo’s intelligent continuous carbon fiber placement, unprecedented structural integrity and stability are achieved.

Hemant Bheda, Arevo Co-Founder and Chairman said:

“This is the first Composite Additive-Manufactured bike frame and it represents an important milestone for the AM industry as Arevo is delivering on the promise of on-demand manufacturing of composite parts in volume now. With the introduction of the Emery ONE, the transformation of the global composite bike industry has begun.”

Renowned industrial designer Bill Stephens of StudioWest collaborated with the Arevo and Franco teams to design the Emery ONE bike frame. He added:

“Arevo DNA offers a new paradigm for product designers, it forever changes how we can design and build anything. This technology allows us to push design boundaries in a way that was impossible until now. Arevo is changing the paradigm to ‘Manufacturing for Design’.”

Finally, the Arevo DNA AM process takes the design and final manufacture of a bike frame from 18 months to just a few days at a significant reduction in product development costs.

What is the free motion printing ?
Conventional 3D printers typically print in 2D on a stacked horizontal plane. By making all axes available, Arevo robotic arm removes design constraints, enables true 3D printing, and provides the freedom to create.

Free motion printing

The frames are in production now at Arevo’s new multi-purpose facility in Milpitas and this achievement with the Emery ONE represents several breakthroughs for bicycle manufacturers, with implications for other industries as well.
These breakthroughs include:

  1. True serial, volume production of AM-made composite parts that are made with thermoplastic materials, which are tougher, durable and recyclable, as compared to brittle and non-recyclable thermoset materials
  2.  A replacement of a laborious manual process with a fully-automated, “lights out” production model
  3. Delivering on the promise of localized manufacturing or “on-shoring,” which creates greater independence for bike brands
  4. A much greater “freedom of design” for bike manufacturers that creates the possibility of fully-customized bikes made on an “on demand” basis, an approach Arevo calls “DESIGN. PRINT. GO”

Hemant Bheda, co-founder and Chairman of Arevo commented:
“This award is a testament to the high performance multi-disciplinary team at AREVO, which comprises 13 PhDs and in computer science, materials science, and robotics from the best universities around the world,” said Mr. Bheda. Team Arevo created the world’s first 3D-printed continuous carbon fiber bicycle frame in production now with a process that takes a small fraction of the time as traditional manufacturing techniques. This is a good start to 2019 and we look forward to building upon our achievements with additional exciting developments the rest of the year.”

The final 3D-printed eBike frame

Emery launches 3D-printed eBike frame

The Emery ONE is born through a partnership with Silicon Valley based Arevo, who specializes in an advanced 3D printing manufacturing process to create a single-piece, ultra-strong, aerospace grade continuous carbon fiber frame.

Emery launches 3D-printed eBike frame

Speed: Bosch Performance Line drivetrain with 63Nm of torque and 600w maximum power output. Available in 20 mph and 28 mph max speed versions.

Emery launches 3D-printed eBike frame

Range: With between 25 and 100 miles of range, you are free to go where you want, without waiting in traffic or breaking a sweat.

Emery launches 3D-printed eBike frame

Terrain: Versatile, all-road frame design is fast and efficient in every kind of terrain.

Emery launches 3D-printed eBike frame

Companies: Arevo, eMery Bikes

Industries: Sports, Leisure & Recreation

Terms: Business, Innovations

This article has been edited by Basalt.Today
This article has been written on JEC Composites Magazine
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