[3D Scanning Case Study] Sports R&D Company Uses "3D Scanning Technology and Model Analysis" to Create World-Class Competition Bicycles
We have previously shared many successful overseas 3D scanning case studies, including: optimizing food production lines, 3D scanning and printing prosthetics, industrialforging die repair... This time, a bicycle manufacturing company successfully applied scanning technology to push their product design crystallization to the World Track Cycling Championships. They were specifically designed for the "2021 Tokyo Olympics" project and have received full approval from the "Union Cycliste Internationale (UCI)."
This demonstrates that mastering 3D scanning technology combined with product development insights can bring business opportunities beyond imagination. Let's see how they transformed the ultra-high-speed WX-R bicycle into a real product!
Challenge
A sports R&D company, Vorteq, needed to digitally capture a series of professional racing bikes in high-resolution 3D for the creation of highly aerodynamic competition bicycles.
Solution
Artec Leo, Artec Space Spider, Artec Studio, Geomagic Wrap
Results
Using a professional handheld 3D scanner, 3D models of multiple racing bikes were captured. These precise 3D models, with the accurate geometry of the bike frames and components, were combined with 3D data to design an exceptional bicycle.
In the world of professional and Olympic cycling, air resistance is indeed a drag. But now, by using the latest handheld 3D scanning technology combined with cutting-edge CFD (Computational Fluid Dynamics) analysis, CAD expertise, and design thinking, UK-based Vorteq, in collaboration with WX-R engineers, has created a bicycle that can slice through the air, taking the cycling industry by storm.
Vorteq WX-R Competition Bicycle (Source: Courtesy of Vorteq)
In a high-speed triathlon, using an aerodynamic bicycle compared to a regular racing bike could mean crossing the finish line minutes earlier in a 5-hour cycling leg. But what about an even faster bike? A bike that can stand out even from the most powerful teams?
For decades, racing bicycle manufacturers have strived to make their mechanical designs the preferred racing bicycles on the road, but largely, their designs have been based on competitors' designs. Wind tunnel testing and CFD testing have been used occasionally. However, a crucial aspect has mostly been overlooked: the speed equation, the riders themselves, their bicycles, and biomechanics. Considering more facets than just competitors is an excellent strategy to outperform them.
“ What is CFD? ”
Computational Fluid Dynamics, which simulates and analyzes the behavior of fluids (such as gases or liquids) under different conditions through computer.
“ What is wind tunnel testing? ”
Through this technology, we can test the performance of bicycles at different wind speeds and directions. This helps us design more streamlined and energy-efficient bicycles, thereby improving riding speed and efficiency.
With years of CFD expertise gained from working in F1 and motorsports, solving the toughest engineering challenges and providing super-accelerated solutions to clients, the design engineers at Vorteq, a TotalSim company, set their sights on creating the world's fastest bicycle.
The first phase of the project required digitally capturing a series of professional racing bikes in high-resolution 3D. After scanning, these 3D models of the bicycles would be used for cutting-edge CFD analysis, combined with the latest wind tunnel testing and research, including analyzing the riding habits of the cyclists themselves (the bike owners). Subsequently, everything would be integrated to create the ultimate aerodynamic racing bike, the Vorteq WX-R.
Vorteq measurement engineers explained how they conducted the scans:
1. "We scanned a series of bikes to obtain precise digital models, then compared them in our CFD system to see the differences in drag, and then made structural adjustments and modifications to the 3D models to improve performance. In this way, we were able to extract the best from multiple bikes and combine them into one design."
2. "At the same time, as we went through the design process, we partnered with SSEH, a sports R&D peer, to analyze the riders of these bikes to understand how they actively generate power and how this affects the entire bike. A lot of invaluable data was obtained here, which is a secret factor in bicycle design for outperforming competitors."
How did 3D scanning help during the mid-term development process?
Engineers placed each rider's bike in a fixed jig and then applied different levels of load to the crank area, adding some flex to the crank to see how much the frame bent. This continued until peak power generation, to replicate the torque through the pedals, cranks, and through the wheel axle. Then, a 3D scanner was used to precisely capture the bike's frame during this process, and deviation maps were generated from these scans, showing how and where the frame bent.
3D scanning significantly streamlined the engineers' workflow
"After importing the scan files into the post-processing software Artec Studio, the bicycle scan was very quick. First, we conducted a simple rough check of the prototype to ensure everything looked complete. Then, we used the eraser tool to delete any unwanted data present in the scan. After that, we performed a global registration using default settings, and the 3D model was already quite perfect."
The next step focused on 'sharp fusion' to process components and rigid structures. Sharp fusion retained all the complex geometric details of the bicycle model that we needed. Then, it was exported as an OBJ file to Geomagic Wrap to transform the 3D data file into a fine 3D model, where some additional design steps were carried out, and then the resulting 3D model was sent to the CFD system."
“ What is Sharp Fusion? ”
It uses a special technique to merge different 3D scan images or models together, making them appear clearer and more detailed. It's like combining several photos into a better group photo, allowing us to see the shape and texture of objects more clearly, thus better understanding their appearance.
After the R&D phase, to bring their creative vision to life, Vorteq partnered with British bicycle manufacturer Worx, which had previously manufactured its own racing bikes but none like the Vorteq WX-R.
The Vorteq WX-R has already competed in races and is planned for the Tokyo Olympics. At the UCI Track Cycling World Championships, its full setup contributed to two medals, three lifetime bests, two national records, and a new Asian record.
“ When looking for a professionalhandheld 3D scanner, it must meet all requirements for accuracy, capture speed, and be designed to capture medium-sized objects in stunning color. In our experience, a powerful scanner can fully capture a professional racing bike in 15-30 minutes.”
【Related Product Recommendations】
1. Geomagic Control X 3D Automated Inspection Software
● Provides new tools for creative metrology and inspection, a workflow-driven planning process, step-by-step inspection, and rich content.
● Suitable for point clouds and probes, data automatically generates easy-to-interpret deviation color maps and automatically analyzes your product in detail.
● Provides comprehensive intuitive measurement, dimension and tolerance tools, automatic inspection of geometric features, real-time deviation tools, or iterative alignment.
● Automates functions using Python programming language, establishing environmental variables and inspection processes to meet company needs.
2. Geomagic Design X 3D Reverse Engineering Software
● Seamlessly connects with mainstream CAD software, including SOLIDWORKS®, Siemens NX®, Autodesk Inventor®, and PTC Creo®.
● Can handle over a billion point cloud data and has a complete set of data processing functions.
● Converts 3D scan data into high-quality feature-based CAD digital models.
● Similar to CAD software, it is easy to learn and use.
● Provides new tools for creative metrology and inspection, a workflow-driven planning process, step-by-step inspection, and rich content.
● Suitable for point clouds and probes, data automatically generates easy-to-interpret deviation color maps and automatically analyzes your product in detail.
● Provides comprehensive intuitive measurement, dimension and tolerance tools, automatic inspection of geometric features, real-time deviation tools, or iterative alignment.
● Automates functions using Python programming language, establishing environmental variables and inspection processes to meet company needs.
2. Geomagic Design X 3D Reverse Engineering Software
● Seamlessly connects with mainstream CAD software, including SOLIDWORKS®, Siemens NX®, Autodesk Inventor®, and PTC Creo®.
● Can handle over a billion point cloud data and has a complete set of data processing functions.
● Converts 3D scan data into high-quality feature-based CAD digital models.
● Similar to CAD software, it is easy to learn and use.
Have you discovered new business insights on product items after reading this? Or are you also considering comparing 3D scanners?
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