3D Printed Bike Frame
Arevo | May – August 2017
- This project occurred before I got very into cycling and working on bikes. Another intern and I designed and prototyped a road bicycle frame made from carbon fiber 3D printing material. This prototype was not rideable, but the company made a rideable frame within the year after this internship concluded.
- The design challenge was to create a lightweight, rideable road bike frame made from 3D printed carbon fiber.
- The tubes are made from two rectangular cross-section 3D printed carbon fiber bars. These bars are fixed to the lugs with epoxy and have spacers epoxied at specific locations between the two bars to increase the moment of inertia. The bars are rectangular, long, and skinny due to the print capabilities for this specific carbon fiber printing material, which was used because it is the strongest material available for carbon fiber 3D printing.
- The lugs are commercial stainless steel double oversized lugs.
- To interface the tubes and metal lugs, we designed and printed connectors from a weaker carbon fiber material that has the capability to print complex geometries that would interface the circular cross-section lugs and two rectangular bars at certain angles and still withstand forces.
- We performed FEA modeling and material testing in our design.
- The frame was designed to interface with standard bike parts, including the headset and fork, press fit bottom bracket, and fixed gear wheels. The picture of the bike does not include the seat post due to a lug brazing defect (seat post was blocked from sliding in).
- Total Frame Weight: 1.79 kg (~4 lbs)
- Total Bike Weight: ~12 lbs
3D Printed Drone
Arevo | July – August 2016
- I designed and 3D printed a drone body out of carbon fiber printing material. I then assembled the drone with the necessary components and flew it.
- Printed 5 different pieces: 1 cockpit and 4 arms with 25% infill using 30% carbon fiber Arevo Labs 3-D printing material
- Standard 450 mm tip-to-tip quadcopter design
- Arms secure into cockpit with dove-tail (no bolts/fasteners needed)
- Assembled with DJI Naza-M2 flight controller, T-Motor Navigator Series MN3110 14.8V 700KV motors, 12×4.5 propellors, 14.8v 1300mAh 40C G-Force Elite Series Lithium-Polymer Battery, Castle Creations Talon 25V Electronic Speed Controllers, M6 Nylon Lock Nuts for Propellors
- Assembled Drone Mass: 1.596 kg (~3.5 lbs)
- Electronic Components mass: .975 kg (2.15 lbs)
- 3-D printed body mass: 0.621 kg (1.37 lbs)
3D Printed Stroller
Arevo | July 2017
- I prototyped a baby stroller made out of 3D printed carbon fiber by purchasing a stroller, creating a CAD model of the stroller, and swapping most of the metal parts with carbon fiber parts that I designed and 3D printed.
- The stroller is intended to be used at trade shows to showcase Arevo’s wide range 3D printing applications.
