Stress-Based Lattice Structure Design for a Motorbike Application [version 2; peer review: 2 approved]

Abstract

Background The “drive by wire” mechanism for managing the throttle is not applied to every modern motorcycle, but it is often managed through a steel wire. Here, there is a cam on the throttle control. Its shape allows the throttle opening to be faster or slower and its angle of rotation, required for full opening, to be greater or less. The maximum angle a rider’s wrist can withstand depends on numerous musculoskeletal mobility factors, often limited by falls or surgery. Methods Using a Progrip knob with interchangeable cams allows the customization of a special cam profile, to ensure the best engine response to throttle rotation and ergonomics for the rider. The use of FEA software and lattice structures, allows to realize a lightweight and efficient design, targeted for fabrication with additive manufacturing technologies. Results The cam was manufactured by exploiting MSLA technology. Finally, a dimensional inspection procedure was performed before assembly. The main result is to have obtained a lighter and cheaper component than the original. Conclusions This study has allowed the design of a mechanical component consisting of innovative shape, light weight, and ergonomics. Furthermore, it demonstrates the effectiveness in the use of lattice structures to enable weight optimization of a component while minimizing the increase in its compliance.

Keywords

• MSLA
• water washable resin
• lattice structure
• nTopology
• Design for additive manufacturing
• Stereolithography tooling
• eng