Motorcycle custom parts made by 3D printers cost 90% less

“Keeping prototyping and manufacturing in-house with a 3D printer ensures that designs never leave the company premises, safeguarding your intellectual property”

Joost Motoren is a specialist in the repair and maintenance of BMW motorcycles. They are known for their client-specific and innovative approach. Where everywhere else people just talked about 3D printing replacement car parts, at Joost Motoren they are actually doing it. Most of the customers are BMW owners who have run into a problem that the specific parts they want are not available. At Joost Motoren they are using a Tractus 3D printer to recreate parts of motorcycles.

They design the part, 3D print them, finish them, paint them and then are ready to put it into the motorcycle. Most parts are 3D printed in ABS. Some are 3D printed in PEI and PEEK, which are high-performance materials that need to be made on their high-temperature 3D printer. Depending on the wishes of the customer the parts are either clear coated or painted.

Challenge and solution

Custom made motorcycle parts

For example, a BMW S1000XR motorcycle has H7 lamps. They wanted to replace the original lamps with Power LED lamps, because the original lamps gave too little light to make the other traffic aware of the presence of the motorcycle. However, the original BMW case was too small. Power LED lamps have bigger cooling ribbons because these lamps give off more heat.

BMW has no optional alternative in its assortment for this, so making it fit would be a lot of work and cost a lot of money. Parts would have to be CNC’d by an external machine shop, which can be a lengthy process if you take the long lead times associated with outsourcing into account. Joost Motoren consulted our partner True Colours about this, and they came up with a better solution together. They decided to 3D redesign the standard case to make the Power LED lamp fit.

With 3D printing technology, it is possible to produce the finished parts in a matter of hours and you no longer have to rely on the schedules of third-party suppliers. Innovative designs are also not shared with anyone else, safeguarding the intellectual property of a company. In no time Joost Motoren and True Colours were able to redesign the original, after which a new case for the Power LED lamps was created and printed using a Tractus3D printer. The lamps can now be found in the BMW. In this particular case, 3D printing was a perfect and affordable service and a logical solution to the problem, even though it did not exist before.

Less production time and costs

The 3D printed parts can be made in a couple of hours and – after a bit of post-processing – will be used as a final part on the custom cars. 3D printing allowed the shop to triple the speed of producing parts while cutting the costs of production with 90%.
CEO Ben Schilperoort: “You think of 3D printing at first as just a prototyping tool, but for a lot of companies it is an end-use process. They are happy they no longer have to rely on the schedules of third-party suppliers and their integrity”.

This case demonstrates how 3D printing can transform the way parts are made in a custom motor building shop. They have been able to triple the speed of production and cut the costs by ten times. While modification projects usually take anywhere from a few days to a few weeks, they were able to finish the part in just one day.

Benefits

  • Designs never leave the company
  • 3D printing shortens the development process
  • You are able to test ideas quickly and discover what does and does not work
  • New iterations have no cost penalties
  • It’s easy to personalize and tweak parts to uniquely fit your needs at no extra cost and in just a matter of hours
  • Engineers can discuss a design with peers or rapidly test the new parts
  • You can verify a design before investing in an expensive molding tool

Results

Competition

With 3D printing, Joost Motoren is able to make custom parts, which can be used for prototyping as well as the final product.

Time

3D printing allowed the shop to triple the speed of production.

Errors

New iterations have no cost penalties, other than the small amount of filament necessary.

Costs

With 3D printing, Joost Motoren is able to make custom parts, which can be used for prototyping as well as the final product.

Confidentiality

Designs never leave the company, so third parties can never claim your innovations for themselves.

2017-12-01T18:43:52+00:00