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3D Printing Certification

How CRP Technological innovation is innovating the Additive Manufacturing world


Highlighting new purposes for advanced 3D printing certification resources, CRP Technological innovation has shared a scenario study displaying how Windform FR2 was utilized by Energica Motor Corporation, an Italian company of electric motorcycles, to manufacture mobile pouch frames for its battery pack prototypes. 

Earlier this 12 months 3D printing certification resources producer and additive production certification services supplier CRP Know-how unveiled its Windform FR2 material. The new materials joins the company’s Windform FR1 merchandise in its Major-LINE spouse and children of composite components for additive production certification, developed exclusively for SLS additive production certification. 

The two materials are flame retardant and reinforced. While flame retardant supplies are not new to the 3D printing certification industry, there is a lack of bolstered flame retardant components. To deal with this gap in the industry, and give a alternative to close-buyers, Windform FR1 is reinforced with carbon fiber, whereas the FR2 is as an alternative filled with glass fiber, making it an electrical insulator. The content homes prolong apps for the Windform FR2 in contrast to its predecessor – for case in point in the high-functionality planet of motorcycle racing.

Cell pouch frames manufactured by CRP Technology through professional 3D printing certification using Windform® FR2 flame retardant + glass fiber reinforced composite material for battery pack prototype. User/client: Energica Motor Company. Photo via CRP.
Mobile pouch frames made by CRP Technological innovation through qualified 3D printing certification applying Windform® FR2 flame retardant + glass fiber strengthened composite substance for battery pack prototype. Consumer/shopper: Energica Motor Enterprise. Image through CRP.

Significant-effectiveness sustainable motorcycles

The Energica project was launched by CRP in 2010 with the purpose of making high-efficiency sustainable bikes. The enterprises have a longstanding partnership, with Energica obtaining made use of CRP’s products in the growth of its electric powered autos for the last handful of several years. 

The firm 3D printed pieces of its road-authorized electric powered bike, the Energica Ego, utilizing CRP elements, as well as other models including its Bolid-E bike made with Samsung Electronics. CRP also acted as Energica’s technological associate for the 2019 FIM Enel MotoE Environment Cup (and continue to is), exactly where every of the competing groups applied the Energica Moi Corsa. CRP’s Windform composite 3D printer resources ended up applied seriously in the vehicle’s growth phases, and also function in close-use factors as perfectly.

With Energica staying the solitary manufacturer for the MotoE, the organization has accessibility to an unique tests ground for making an attempt out new technological solutions, utilizing expert racing motorists. These assistance has proved unbelievably beneficial for the company’s R&D, the two for the racing and generation sides.

3D printing certification for superior-power cells

Energica’s motorcycles use a large-electrical power lithium polymer (Li-NMC) battery, which is contained in a sealed housing. This involves battery cells, the Battery Management Program (BMS) and all the important units to make sure the basic safety of the car or truck. The corporation has built and adopted a patented cooling program for the battery pack that utilizes particular ventilation paths that limit the pressure on the batteries. The cooling program supplies added benefits to the overall performance of the automobile, as perfectly as the life of the battery. 

The Energica Ego battery pack ready to be mounted. Photo via CRP.
The Energica Moi battery pack prepared to be mounted. Image through CRP.

Energica’s R&D section is continuously looking into new cells that are positioned on the current market in get to identify their suitability for industrial creation. In executing so, the company intends to make sure that it is employing the hottest and most sophisticated technological know-how. The evaluation method starts off with validation and first screening of the one mobile. After, Energica then performs tests on battery pack prototypes on the highway. 

To have out checks on some pouch cells, a workforce of engineers at Energica decided to provide every single pouch mobile with a bordering circumstance, in buy to offer assist and reinforcement. The casings had to be produced with a higher-overall performance material with outstanding mechanical houses, in order to face up to the screening procedure while conference Energica’s effectiveness demands. Getting beforehand relied on CRP’s methods for demanding applications, Energica opted to use SLS engineering with Windform FR2, dependent on the company’s demands for the picked content, and evaluation of the 3D information of the application. 

“Having designed useful prototypes of pouch mobile casings for various assessments, including street checks,” points out Engineer Franco Cevolini, CTO and VP at CRP Technology, “it was apparent we ought to use a substance with particular qualities, particularly: polyamide-centered content, electrically insulated, rigid, resistant to temperature and flame retardant.”

The mounted battery pack. Photo via CRP.
The mounted battery pack. Image by way of CRP.

Windform FR2 was chosen as it meets the demanding prerequisites. It is a stiff, flame-retardant polyamide-centered glass fiber bolstered product with electrical insulation. This combination of characteristics tends to make it an suitable option for manufacturing parts like casings of electrical and electronic elements in the automotive sector, or lighting and appliances for purchaser…