"The redesign resulted in a 48% weight reduction
in the part."
Mikhail Zhmaylo, CompMechLab
Altair Inspire in the Design Process
The team at CompMechLab set out to redesign the part for additive manufacturing. The team
knew that it could likely use the current part and with the freedom of additive manufacturing
simply print the current geometry, however, it wanted to truly attain all of the benefits of the
process and knew it could use Altair Inspire to achieve these benefits. CompMechLab used Altair Inspire to
apply all of the loads, shape, and boundary conditions and ran multiple rounds of optimization
on the part. Mikhail noted, “In total the whole redesign process of the part took less than
a couple of weeks. Altair Inspire definitely helped to expedite this process.” After the team had
determined the final design for the part, they ran FEA analysis to ensure that it would meet
all of the required loads.
Once the design was complete and verified, CML AT organized 3D printing and post-processing
of the prototype. Electron beam melting technology by Arcam allowed the production of the part
in Ti6Al4V within a very short time frame. CML AT is now responsible for all future production
cooperation, as well as technical support for Triton Bikes. While the original part weighed 198g
and was produced with a very timely and wasteful process, the new part weighs in at 102g and
can be produced in a single-step with very little waste. In total, with the new process and design,
the part can be produced in two hours.
The redesign of the part was extremely successful, Triton is currently working on finishing up the
integration of the new design into their customized bike frame. In the future the team at Triton,
with the help of CML AT and CompMechLab may also explore redesigning the frame’s front yoke,
as well as some of the frame's structural nodes.