Case History Archivi

Made by Aliens

Apr 11, 2024 | Case History, PA 11

Case History

BASF Forward AM + JNORIG + Prosilas

“ I wish they looked like they were made by aliens” says Javier Giron, creative director of JNORIG.

Exploring Futurism and Sustainability in Fashion

In the heart of Barcelona, where diversity meets innovation, the avant-garde fashion brand JNORIG thrives.

Led by the visionary creative director, Javier Giron, JNORIG challenges conventions, embracing a futuristic aesthetic that celebrates individuality and self-expression.

In a quest to bring otherworldly designs to life, JNORIG embarked on a journey that led to an extraordinary collaboration with Prosilas and BASF Forward AM, resulting in the creation of truly remarkable pieces that seem “made by aliens.”

Challenge: Bridging Fashion, Sustainability, and Innovation

Fashion, by its very nature, is a realm of constant exploration and reinvention. It is a space where new ideas merge with cutting-edge technology and sustainable practices. It’s a shared DNA with the 3D printing industry.

When JNORIG expressed their desire for designs that defied convention and embodied sustainability, Prosilas and BASF eagerly accepted the challenge.

The task at hand was to produce jewelry pieces with unconventional shapes using sustainable materials, all while maintaining an impeccable level of surface finishing akin to creations from another world.

This challenge perfectly aligned with Prosilas and BASF’s commitment to pushing the boundaries of 3D printing technology and sustainable manufacturing.

Solution: Ultrasint® PA11 – A Sustainable Innovation

Prosilas, in collaboration with BASF Forward AM, introduced Ultrasint® PA11 into their Selective Laser Sintering (SLS) systems.

Ultrasint ®PA11, made from castor oil, represents a bio-based alternative to traditional materials like PA12.

Its exceptional toughness, high elongation at break, and elasticity make it an ideal choice for creating resilient, impact-resistant parts.

Notably, Ultrasint® PA11’s biocompatibility and safety for human contact make it suitable for a wide range of applications, including medical devices and sensitive sectors.

Moreover, BASF’s commitment to sustainability extends beyond material innovation; they work closely with castor farming communities in India to enhance productivity and reduce environmental impact.

“Partnering with Prosilas on the ‘MADE BY ALIENS’ project highlighted our commitment to sustainability and innovation. Using our eco-friendly Ultrasint® PA11, they pushed the boundaries of 3D printing to bring JNORIG’s futuristic visions to life. This collaboration exemplifies the transformative power of combining cutting-edge technology with creative ambition, breaking the manufacturing boundaries in fashion, and beyond” says Marco Cristofori, Senior Product Marketing Manager, BASF Forward AM

Collaboration Process: From Concept to Catwalk

The collaboration between Prosilas, BASF, and JNORIG was characterized by innovation, efficiency, and creativity.

Within just one month from the initial request, the teams transformed JNORIG’s visionary designs into tangible reality.

Using state-of-the-art 3D printing technology and advanced materials, they produced jewelry pieces that transcended conventional boundaries.

The designs, characterized by fluid silhouettes and otherworldly aesthetics, captured the essence of JNORIG’s futuristic vision.

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Fashioning a Sustainable Future

The culmination of this collaborative effort was showcased at the Barcelona fashion show on April 10th, 2024.

The jewelry pieces, crafted from Ultrasint® PA11, not only mesmerized the audience with their striking designs but also highlighted the potential of sustainable materials and advanced manufacturing techniques in the fashion industry.

JNORIG’s commitment to sustainability and innovation extends beyond individual creations; it represents a larger movement towards a more responsible and inclusive fashion ecosystem.

Through the fusion of creativity, technology, and sustainability, JNORIG, Prosilas, and BASF are pioneering a new era in fashion—one that is both visionary and conscientious.

In a world where the boundaries between imagination and reality blur, collaborations like these serve as a testament to the transformative power of creativity and innovation. As we venture further into the future, guided by the spirit of exploration and sustainability, the possibilities are as limitless as the cosmos themselves.

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Javier Giron, designer JNORIG

FOCUS

JNORIG

JNORIG is a brand dedicated to diversity and breaking societal norms, celebrating individuality regardless of background, religion, or gender. With architecture-inspired designs and gender-fluid silhouettes, they blend cultural elements and opposing concepts for a unique artistic vision. Javier Giron’s innovative garments combine precision, comfort, and sustainability, embodying a futuristic aesthetic. Tailored for different body types, JNORIG’s designs promote confidence and self-expression, inviting wearers into a universe of disruption and mystique.

BASF Forward AM

BASF Forward AM provides 3D printing solutions along the entire Additive Manufacturing value chain: From consultancy and development, through bespoke design, digital simulation and prototype printing, to finishing and exhaustive component testing – Forward AM provides you with exactly what your business needs. Whichever material you require for your specific project, Forward AM offers you the world’s largest selection of 3D printing materials and service solutions.

Prosilas

Established in 2003 and part of the Prototal Group since 2022, Prosilas stands out as an advanced service provider that integrates various technologies, from 3D printing to vacuum casting and injection molding.
With a strong customer focus and proven experience, Prosilas is a reliable, fast, and sustainable partner for the industry. The company is a reference point for series production, with a long-term vision and the commitment to completing the production cycle by satisfying every phase.
Prosilas offers its expertise in industrial processes and polymer materials to meet the new market demands. Prosilas promotes the research of innovation on products and solutions, with the aim of reducing waste and intensifying research in an efficient and sustainable way.

From idea to prototype in 4 months, Bimota streamlines times and costs for its motorcycles with Prosilas’ 3D printing.

Jan 12, 2024 | Case History, News Prosilas

Bimota + Prosilas Case History

Thanks to Prosilas’ additive manufacturing, the Rimini-based company develops new high-performance models within a few months. This cuts down both time and costs, resulting in absolute excellence on the road and the track.

Bimota is the historic motorcycle manufacturer, founded in Rimini in 1973. Over the years, the company has undergone various changes and evolutions, leading to its revival through the acquisition by Kawasaki Heavy Industries: 49.9% in 2019, eventually increasing to 100% at the beginning of 2023. Now, Bimota can rely on Kawasaki’s technology supply, including engines, and its sales network.

“We started designing the new Tesi H2 right away: carbon bodywork and a supercharged, high-performance engine with the highest category performance, boasting 230 horsepower for the Euro 4 version and 200 for the Euro 5,” confirms Pierluigi Marconi, Bimota’s technical director. “However, we soon encountered an unforeseen obstacle – the Covid pandemic and the need to work from home. It turned out to be an opportunity to change our approach and design the entire motorcycle in 3D, opening up a range of interesting possibilities.”

Pierluigi Marconi , Bimota Tecnical Director. Tesi H2 and KB4

In the Bimota workshop, the prototype of the Tesi H2.

From 12 to 4 months for the prototype.

Having the 3D model of each part of the motorcycle is undoubtedly advantageous because it allows for virtual testing and evaluating the actual correctness of certain decisions made by the designer on the screen.

However, “there still comes a time when you have to touch the pieces, assemble them, and understand how they behave to determine if the choices made are correct,” adds Marconi. “In the past, it was necessary to manually create clay prototypes, from which rapid molds for fiberglass had to be constructed. A costly and laborious process, whose results were not always precise.

Now, with the 3D files available, we have the opportunity to have them printed through rapid prototyping services: this is how we got to know Prosilas.”

From the idea to the first exhibition mockups, it is possible to reduce the timeline from approximately 12 to 4 months, with a clear reduction in associated costs. Once the validity of the project is confirmed, the production of equipment begins. Marconi continues, ‘The development proceeds very quickly, the fine-tuning of components takes a few weeks, and a 3D-printed prototype is obtained from the file within a couple of days.

We check if the geometries and modifications are correct or if further adjustments are needed. In this case, it is sufficient to send the file back to Prosilas to obtain the new printed piece for testing. Typically, with a couple of iterations, we achieve the best possible result. Previously, mold adjustments were necessary, a very costly activity: at best, it required some modifications, and sometimes even a complete remake.”

The Bimota staff with the prototype of the Tesi H2

Track testing with the Tesi H2

Prosilas’ 3D printing also works on the track.

For a company like Bimota, the result is evident in on-track testing: “When you book a test day and organize the trip for some engineers from Japan,” explains Marconi, “you cannot afford a component delivery failure. A test day can cost us tens of thousands of euros, and today, no one is willing to squander such an investment.”

Therefore, it is necessary to find a partner capable of producing even the most complex components, which are challenging to develop solely based on fluid dynamics simulation. The multiple variables at play, such as air temperature or flow direction, make it more practical to design a high-quality 3D file for practical testing on the road

And this is where Prosilas’ rapid prototyping proves reliable and valuable. “Once we designed some body parts and ducts, we obtained the printed pieces in a day and tested them,” explains Marconi. “The use of Nylon loaded with glass fiber (PA12 GF) is ideal in terms of mechanical strength and resistance to high temperatures. Some parts are indeed very close to the exhaust system or radiators and need to endure for a long time, providing us with useful data to understand if we are on the right track. Additionally, it is a material that does not deform, a very useful characteristic when used for the coupling of body parts.”

Tesi H2 marked the beginning of a path entirely dedicated to 3D for Bimota. With the KB4, featuring an appealing Vintage Inspired appearance, Prosilas’ additive manufacturing allowed, for example, the creation of a complex air duct system. TERA, the latest addition from the Rimini manufacturer, stood out at the last edition of EICMA – Milan, thanks to two exclusive kits, which will soon be updated with additional aerodynamic appendages.

Frontal view of Tesi H2 and KB4

The respect for established timelines

For Bimota, the initial experience with 3D printing was not immediately positive. “We had worked with suppliers who sent us deformed components, out of tolerance, some even delaminated,” admits Pierluigi Marconi. ‘So the benefits of rapid prototyping were nullified because if you have to intervene on a piece and it doesn’t perform as expected in tests, you can’t know if the fault lies with the design, the material, or the printing. Also, for this reason, in my opinion, the cost factor is secondary: spending 10% less but having parts that do not meet our expectations means wasting money. The same goes for delivery times: if I cannot rely on a supplier, it means it’s the wrong one. When we met the Prosilas staff, on the other hand, we immediately noticed a great attention to our needs and the challenges of our work.”

Another critical detail is related to timelines: while prototyping allows for a reduction in development times, it also demands that the supply chain be absolutely reliable. Another challenge that Bimota and Prosilas have overcome together. “Prosilas is the most accurate and punctual suppliers we have ever had,” concludes Marconi. “We provide them with the file, and we get a delivery timeline that is crucial for us, as we base subsequent activities on it.”

Render 3D Bimota KB4

Pierluigi Marconi e his staff

A future full of challenges for Bimota

Now that Bimota designs new models in 3D and leverages the additive technology of Prosilas, both the time and cost of the process have undergone a significant reduction. The company remains in constant search of new ideas and solutions to make further advancements in every aspect: from the performance of their motorcycles to the reduction of development budgets, always keeping an eye on overall timelines.

The expertise and guidance from Prosilas experts can once again prove to be the winning strategy to achieve desired results and solidify Bimota’s success in the market

BASF Forward AM + Prosilas: Validation of TPU88A in Ultrasim® Lattice Engine software

Oct 26, 2023 | Case History, News Prosilas, TPU - SLS Material

BASF Forward AM + Prosilas Case History

A highly productive and longstanding collaboration has been established between Prosilas and BASF Forward AM over the years. This partnership has given rise to esteemed projects, including the research and production of Philipp Plein’s Skeleton Sole and the comprehensive Lube Volley Case Study.

When BASF Forward AM approached us for cooperation, we welcomed the opportunity with great enthusiasm.

Our involvement centered around the characterization of 3D printed lattice structures made of Ultrasint® TPU88A from BASF Forward AM. It aims to offer users pre-selected, validated lattices in Ultrasint® TPU88A on SLS machines to get a head start in their lattice application development.

For this, the validated lattices will be integrated into BASF Forward AM´s lattice ecosystem consisting of Ultrasint®TPU 88A Lattice Test Pads, Ultrasim® Lattice Library, and Ultrasim® Lattice Engine.

Prosilas will provide excellent print service with an in-dept know-how on printing lattice structures.

Prosilas successfully and expertly utilizes BASF Forward AM´s Ultrasint® TPU 88A. Annually, we process approximately 2000 kg of this TPU in our SLS machines.

BASF FAM Ultrasim® 3D Lattice Engine_GIF

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Ultrasim® 3D Lattice Engine

What is Ultrasim® 3D Lattice Engine?

Ultrasim® 3D Lattice Engine, powered by Hyperganic, is a software application designed to efficiently populate geometric volumes with lattice structures. To achieve this, the software incorporates two key inputs: the STL file of the component requiring lattice infill and a pressure map for performance modulation.

Users can select the specific lattice structure type and hardness parameters from either the 3D printed Lattice Test Pad database or the Ultrasim® Lattice Library, a library containing all characterized lattice structures with in-depth mechanical data.

Upon making these selections, the software autonomously generates the chosen lattice structure within the specified volume. This process renders the file ready for subsequent 3D printing operations.

What is the Ultrasim® 3D Lattice Library?

All the results of the lattice characterization is stored in a library named Ultrasim® 3D Lattice Library. This library allows users to filter lattices by application (Footwear, Protection, Seating), by technical requirements and compare the strain-strain curves for different lattices structures. This way users can much easier find and identify the right lattice. Here you find more information about the library: Ultrasim® 3D Lattice Library .

Exaples of Lattice structure

Lattice Test Pads

What are the Lattice Test Pads, and what is their purpose?

Lattice Test Pads are the 3D printed version of the are Ultrasim® 3D Lattice Library.

They are 3D-printed TPU blocks divided into sections that specify the cell size and beam diameter. Each section provides information regarding the structure classification and hardness.

These Lattice Test Pads come in three types: footwear, seating, and protection. Each type features a lattice structure suitable for its respective application, such as shoe soles, seat cushions, headrests, or various protective elements.

TPU: incredibly flexible material in every sense

It is a thermoplastic material widely utilized in SLS 3D printing due to its exceptional elasticity, rebound, durability, and resistance to tearing, fatigue, and abrasion.

Lattice structures are repeating patterns composed of cells, beams, and nodes that aim to replace foam applications using a single material but different shore hardnesses.

There are countless variations of lattice structures, each exhibiting distinct mechanical behaviors.

Based on an in-depth study of TPU lattice structures, BASF Forward AM successfully characterized and validated lattice structures based on their behaviour for various applications.

This validation allows to pre-select lattices application in various industrial sectors, namely Footwear, Protection, and Seating.

Know more about TPU

Three types of Lattice Test Pads :footwear, seating, and protection

Roberto Nasini, Senior Technician Prosilas

Contribution of Prosilas

Prosilas has been involved in the lattice characterization process, providing various prints of the 3D Lattice Test Pad samples that allowed BASF Forward AM to conduct in-depth studies. These data were essential for furthering the progress of the software.

To ensure that the software consistently delivers high-quality results over time, specific machine parameters have been established for the fabrication of these structures. These parameters have been designed to set a printing standard, ensuring that software users obtain consistent and reliable results. This commitment to quality and consistency is crucial for the success and effectiveness of the software.

About BASF 3D Printing Solutions GmbH

BASF 3D Printing Solutions GmbH, headquartered in Heidelberg, Germany, is a 100% subsidiary of BASF. It focuses on establishing and expanding the industrialization of 3D printing applications under the Forward AM brand with advanced materials, system solutions, components, and services in the field of 3D printing.

BASF 3D Printing Solutions operates in an agile structure to create customer value with complete 3D printing solutions, in collaboration with partners, for the most innovative applications. It cooperates closely with the global research platforms and application technologies of various departments at BASF and with research institutes, universities, startups and industrial partners. Potential customers are primarily companies that intend to use 3D printing for industrial manufacturing. Typical industries include automotive, aerospace and consumer goods.

For further information please visit: www.forward-am.com.

Basf-Prosilas-Test-PAd-Ultrasim-Marius-Haefele-tpu-sls

Marius Haefele, Basf Product Manager

Get your Lattice Test Pads

Lube Volley and Prosilas together to win, with the support of 3D printing

Jul 4, 2023 | Case History, News Prosilas, TPU - SLS Material

Lube Volley + Prosilas Case History

What Prosilas and Lube Volley have in common is not only their city of origin, Civitanova Marche, but also their shared pursuit of challenges and desire to succeed. For the esteemed Marche team, this translates into winning trophies and championships. Meanwhile, for Prosilas, it means constantly seeking innovative solutions to support the development of an increasingly demanding industrial market. The collaboration between the two companies was recently solidified through a sponsorship agreement, which prominently displays Prosilas’ name on the volleyball team’s uniforms. Additionally, they engage in a strong joint effort that connects sports achievements with the utilization of additive manufacturing.

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Lube Volley, Prosilas-supported club is the most successful in the 21st century

Champion of Italy 2022, Lube Volleyball is an acclaimed team, boasting in its list of victories a World Club title, seven league titles (the last three won consecutively), two Champions Leagues, seven Italian Cups and four Italian Super Cups, three CEV Cups and one Challenge Cup. The team expresses a very high technical level of play, capable of always competing at the top: and when playing at high levels even small details can make a difference.

Lube Volley, the team

A tangible collaboration, thanks to 3D printing

When Enrico Diamantini and Ivan Zaytsev, two prominent athletes from the club, expressed their need for new hand protection devices during games, the relationship between Lube Volley and Prosilas evolved beyond a simple sponsorship. Prosilas immediately utilized its expertise in 3D printing to develop an innovative, customized, and tailored solution for both players.

‘We took the opportunity to get even closer to the world of medicine and sport, trying to develop a truly useful and professional application,’ says Vanna Menco, CEO Prosilas

Diamantini required an alternative to the temporary brace he had been using to support his injured right little finger, while Zaytsev needed a replacement for the medical tape he typically used to stabilize his fingers during high-impact phases of the game.

Ivan Zaytsev _ Enrico Diamantini _ lube Volley_ prosilas

Ivan Zaytsev and Enrico Diamantini

The previous solutions had limitations in terms of materials, lacking of technical performance, reusability, and customization, which resulted in a sub-optimal playing experience. However, with the advent of 3D printing, Prosilas believed that they could overcome these limitations and produce custom-made and reusable devices with exceptional speed and precision.

For Diamantini, the old brace was rigid, bulky, and therefore uncomfortable. The negative impact on his ball touch led him to use it sporadically and only for the minimum required time. Similarly, Zaytsev sought a custom-made, reusable alternative that provided better sensitivity compared to traditional medical tape.

Through their collaboration with Prosilas, both athletes found the solution they were looking for, addressing their specific needs and improving their playing experience on the court.

Fast and successful product development

The initial phase of the project focused on acquiring the 3D models of Diamantini and Zaytsev’s hands using the Gom Atos 5 3D scanner, which involved scanning plaster casts. Subsequently, the design phase commenced, incorporating reverse engineering techniques to accurately model customized designs. These designs were tailored to protect and immobilize the injured joint in one case, and provide comfortable support in the other. The devices underwent testing and, with valuable feedback from the athletes, were progressively refined to achieve the best possible results.

“The responsiveness of additive technology is truly remarkable. The initial contact with the players took place in October 2022, and after just five rounds of improvements, we were able to arrive at the final version of the devices for both players within a very short timeframe,” states the CEO of Prosilas.

3D scan of Ivan Zaystsev’s right hand

3D design through reverse engineering of protective devices

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TPU protective devices being tested on the cast of Ivan Zaystsev’s right hand

TPU: a strategic choice

To create these customized and highly comfortable devices, Prosilas opted for BASF’s TPU Ultrasint 88a due to its flexibility and mechanical impact resistance. Thermoplastic polyurethane (TPU) is an elastic polymer known for its versatility and resilience. It can withstand shocks, abrasions, tears, chemical and weathering agents, and is impermeable to water and gases.

TPU is often considered the intersection between rubber and plastic, thanks to its physical characteristics, wide range of hardness options, and flexibility without the need for plasticizers.

For the initial test with Diamantini, three different TPU models were created using SLS (Selective Laser Sintering) technology, each with varying thicknesses of 1, 1.5, and 2 mm. TPU allows for slight variations in thickness, enabling flexibility in the final product.

For Zaytsev, an initial set of devices was produced with a consistent thickness of 2 mm to provide greater rigidity. Additionally, a lateral cut was made to improve the fit of the devices for him.

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3D design through reverse engineering of protective devices

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TPU protective devices for Enrico Diamantini in three different thicknesses: 1, 1.5 and 2 mm

Testing phase and results

“The results achieved through the utilization of additive technology are undeniably positive,” remarks Vanna Menco. “This is further corroborated by the outcomes of resistance tests conducted on the material by our supplier, BASF 3D Printing Solutions.”

The testing phase was a critical step in the process. Collaborating with BASF, an effort was made to replicate a volleyball game in a laboratory setting. This involved evaluating the material’s chemical resistance, short and long-term durability, as well as color stability.

To assess the material’s mechanical stability, strength tests were conducted after 30 minutes, 7 days, and 14 days, with the parts immersed in synthetic sweat.

Tensile strength and elongation at break were measured at these intervals. Furthermore, a sudden impact test was performed to simulate crushing, and no significant changes were observed. The color measurement, which determined its stability over time, confirmed that there was no yellowing or noticeable alteration after 14 days. These results provide evidence of the material’s reliability and longevity.

Tensile samples _ tpu_ basf _ prosilas _ lube volley application

TPU testing samples

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Sudden impact test results

The remarkable durability and strength of the custom 3D-printed devices can be deduced from the absence of significant degradation observed during testing. This ensures the longevity of the product even under repeated stress and in special chemical conditions. Apart from the scientific findings, the enthusiastic feedback from the athletes themselves confirmed the positive results and the significant improvement in playability and game feel.

“I recommend the protection systems made by Prosilas to everyone. Because they are customized, they give maximum comfort in every technical gesture. It’s like not having them!”

says Enrico Diamantini, who used the device during his recovery from a dislocation.

Ivan Zaytsev, on the other hand, continues to use the customised devices on his hands. He says:

“Thanks to Prosilas, I immediately felt comfortable with hitting the ball, the four braces were efficient and above all eco-friendly given the amount of tape they save me!

prosilas_lube_volley_ivan_zaytsev_in_gioco

Enrico Diamantini _ lube Volley_ prosilas

The combination of improved performance, stable feel, durable material, and complete customization results in an overall increase in comfort for athletes during competition, leading to an enhancement in playing performance.

Customization has become an essential trend in the world of ultra-competitive champions, and additive solutions go above and beyond by offering specific shapes and characteristics tailored to each individual athlete’s needs.

Working with BASF 3D Printing Solutions

BASF 3D Printing Solutions, operating under the Forward AM brand, is a division of BASF New Business GmbH that is specialized in advanced materials, system solutions, components, and services in the field of 3D printing. With a lean structure and an agile mindset akin to a start-up, BASF 3D Printing Solutions is well-equipped to cater to the diverse needs of various industries by offering innovative and customized services. The company works closely with other departments within BASF, research institutes, universities, start-ups, and industrial partners to serve customers in automotive, aerospace, consumer goods, and other product categories.

The partnership with BASF 3D Printing Solutions holds significant strategic importance for Prosilas, further solidified by the mutual respect between the two companies.

“Prosilas brings extensive experience in printing our flexible TPU materials, ensuring the consistent delivery of superior quality parts,” explains Tobias Haefele, Product Manager Powder Bed Fusion. “We greatly appreciate their exceptional creativity,” he continues, “and their attitude to push the limits of the 3D printing market, paving the way for new applications, which align with our vision. With their specialist knowledge and established presence in sectors such as fashion, they have earned our trust as a reliable partner in consistently delivering exceptional products over the years. At BASF 3DPS, we are excited to continue our journey with Prosilas, forging a promising future for additive manufacturing.”

KTM chooses Prosilas 3D printing to ride in the wind

May 8, 2023 | Case History, News Prosilas, Pa603cf Carbon fiber

Ktm + Prosilas Case History

Passion for speed meets 3D printing innovation

Since the beginnings of 3D printing, one of the sectors that has most perceived and grasped its potential is undoubtedly racing and motorsport. The demand for parts and components with high mechanical performance, but in limited production runs and tight deadlines, make additive manufacturing the ideal choice for those who produce high performance cars and motorbikes.

This is well known by the Austrian company KTM, whose Aerodynamics and Factory Racing departments have persistently researched and developed revolutionary solutions, not only for the production of functional prototypes, but also for end-use components, to be used both in the wind tunnel and on the track.

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Brad Binder & Jack Miller, motorbike RC16 Red Bull KTM. MotoGP 2023

A partner for 3D printing of carbon-filled nylon elements

It was precisely with a view to creating parts capable of exceptional performance, not only mechanical but also aerodynamic, that the collaboration between KTM and Prosilas was born. In particular, Prosilas’ role is to work alongside the Austrian giant as a partner for the 3D printing and finishing of parts in Polyamide PA2200 added with carbon fibre using SLS technology. A true additive manufacturing process in Nylon with carbon that, thanks to the printing parameters specifically studied by Prosilas technicians for the EOS P770 printer, has also been proposed for large format parts (680x370x540 mm chamber). Prosilas is the only company on the European scene that can offer this kind of 3D printing for objects and components of this size in PA 603 CF material.

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Aerodynamic appendix for the motorbike KTM RC16 MotoGP

Brad Binder, Red Bull KTM, MotoGP RC16 Circuit Ricardo Tormo

From simulations to the wind tunnel: what were KTM’s objectives when you chose Prosilas as your partner?

“The desire was to identify and develop additive-moulded materials that could undergo post-processing to bring the surface finish up to the levels required for our aerodynamic needs,” says Daniel Marshall Team Leader Aerodynamics at KTM: “In particular, we needed to improve the correlation between simulations and subsequent testing, and then possibly produce parts that could cope with track tests and even race events. Thanks to the qualities of PA 603 CF and the surface finishes offered by Prosilas, we can now have parts that fully meet our requirements. We have been able to decisively improve the correlation between computational simulation and wind tunnel testing“.

Vanna Menco, CEO Prosilas, Noemi Rossi, Sales Manager Prosilas, Daniel Marshall Team Leader Aerodinamics KTm , Michele Paolinelli Sales Account Prosilas

From right to left: Vanna Menco, CEO Prosilas; Noemi Rossi, Sales Manager Prosilas; Daniel Marshall Team Leader Aerodinamics KTM; Michele Paolinelli Sales Account Prosilas @ KTM Factory Racing

Constant comparison in the name of optimisation

Highly innovative results, therefore, achieved through an ongoing collaboration between KTM and Prosilas to combine aerodynamic and engineering expertise with that of additive manufacturing: “The choice of materials and surface and post-processing finishes was made in constant collaboration with Prosilas,” explains Daniel Marshall. “Thanks to this partnership, further progress was made in optimising the components in terms of weight, rigidity and waste reduction“

What made KTM choose 3D printing over the traditional methods previously used?

“We decided to go for 3D printing for two very specific reasons: short lead times and minimal quantities,” concludes Daniel Marshall: “We usually produce test parts in one-offs, so traditional production processes are not applicable in terms of both cost and delivery time.

Additive technology allows finished parts in production timescales that are unthinkable for any other technology. For example, eight aerodynamic appendages for the tail of the KTM RC16 MotoGP motorbike were printed and finished within just four days of the order being placed. An astonishing result, which only reaffirms the now inseparable link between racing and motorsport and 3D printing.

A story, the one between Prosilas and the historic KTM, that once again confirms Prosilas’ commitment to being a winning ally to industrial production.

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Appendice aerodinamica per la moto KTM RC16 MotoGP

Press Release

Armotia Case History

Apr 9, 2023 | Case History, Finishing, News Prosilas, PA12 ALU-SLS Material

Armotia + Prosilas Case History

Prototypes of electric motorcycles: the support of 3d printing.

Prosilas played a key role in the realization of the Armotia project, a company based in Osimo that is dedicated to the design and production of electric motocross and enduro motorcycles. Thanks to the collaboration between these two companies, it was possible to create innovative and high-quality prototypes that represent a true revolution in the world of motorcycling.

Armotia: the project

ARMOTIA presents DUE X and DUE R, the first two electric series motorcycles with two electronically controlled distribution drivetrain.

Our motorcycles have exceptional traction characteristics that will give you amazing riding sensations allowing you to experience every type of track, on and off road, as never before.

Besides all this, ARMOTIA offers standard intelligent features and possibilities. Such as an integrated smartphone to record videos, check performance, save telemetry data, and share all your routes. Or the possibility to personalize the most appealing parts of the fairings with a 3D printer, to make the most special motorcycles even more “special” that you have ever seen. Because if it is true that two wheels move the soul, with ARMOTIA you will discover that two-wheel drivetrain definitely does it better.

From the Armotia website.

Prosilas’s expertise

Armotia has relied on 3D printing technology for the production of parts and components necessary for the creation of the DUE R and DUE X motorcycle prototypes. In this context, Prosilas has provided valuable support thanks to their expertise in materials and finishes for 3D objects.

Thanks to the consultancy provided by Prosilas, Armotia was able to choose the most suitable materials for the realization of their prototypes, ensuring a high level of resistance and surface finishing: PA 12 ALU and glass-filled polyamide (PA12 GF) for fairings and shells.

PA12 aluminium filled is a very resistant material that presents a good surface finish, making it ideal for the realization of parts that require high-quality finishing. Moreover, this material can be easily painted, allowing for further customization of the prototypes.

On the other hand, the glass-filled polyamide is a highly resistant material, which is perfectly suited for the production of parts that require greater robustness, and also CNC treatments.

Thanks to Prosilas’ consultancy, Armotia was able to choose the most suitable material for each specific application.

This synergy shows how 3D printing and the consultancy of specialized companies like Prosilas can make a difference in the realization of innovative and high-quality projects.

Post-processing treatments: painting

In addition to advice on the optimal choice of materials, we offer advice on which post-process treatment is the most suitable to achieve the best possible result.

The painting service allows to obtain parts in different customizable colors with a surface finish similar to that of the parts produced with injection molding. Our finishing department is able to replace the entire range of RAL colors and special colors according to customer requests.

Painting is an important aspect to consider in the production of parts in 3d and it gives an added value allowing to get an aesthetically appealing prototype and very close to the final product.

Thanks to advanced technologies and materials, the prototypes and series produced in Prosilas can also have matt, glossy and metallic finishes or resistant to UV rays or to hydrocarbon.

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