[3D Scanning Case Study] A sports R&D company uses 3D scanning technology and model analysis to create world-class racing bicycles.
We've previously shared many successful overseas 3D scanning case studies, including: helping optimize food production lines , printing prosthetics after 3D scanning , and industrial applications . Forging die repair ... This time, another bicycle manufacturer has successfully used scanning technology to bring their product design to the world-class track cycling championships. They were specially designed for the "2021 Tokyo Olympics" and have received full recognition from the "Union Cycliste Internationale (UCI)".
This proves that if 3D scanning technology can be mastered and combined with product development insights, the business opportunities it brings will far exceed expectations. Let's take a look at how they designed the ultra-high-speed WX-R bicycle into a real product!
challenge
A sports research and development company, Vorteq , needed to digitize a range of professional racing cars in high-resolution 3D to create highly aerodynamic racing bikes.
Solution
Artec Leo, Artec Space Spider, Artec Studio, Geomagic Wrap
result
Using a professional handheld 3D scanner , 3D models of multiple racing bikes were captured. These precise 3D models, with accurate geometry of the bike frames and components, were combined with the 3D data to design an extraordinary bicycle.
In the world of professional and Olympic cycling, air resistance is indeed a barrier. But now, by using the latest handheld 3D scanning technology combined with cutting-edge CFD (Computational Fluid Dynamics) analysis, CAD expertise, and design concepts, UK-based Vorteq, in collaboration with engineers at WX-R, has created a bicycle capable of moving through the air, setting a new trend in the cycling industry.
Vorteq WX-R racing bike (Source: Courtesy of Vorteq)
In high-speed triathlons, using an aerodynamic bike compared to a regular racing bike might mean crossing the finish line a few minutes earlier in the 5-hour cycling phase. But what about an even faster bike? A bike that could even outperform the strongest teams?
For decades, racing bike manufacturers have strived to make their mechanical designs the racing bikes of choice on the road, but to a large extent, their designs have been based on those of their competitors. Wind tunnel testing and CFD testing are occasionally used. However, a crucial aspect is often overlooked: Formula One speed, the riders themselves, their bikes, and biomechanics—considering more aspects than the competitors is an excellent strategy to win.
What is CFD ?
Computational fluid dynamics uses computers to simulate and analyze the behavior of fluids (such as gases or liquids) under different conditions.
What is a wind direction test ?
This technology allows us to test the performance of bicycles under different wind speeds and directions. This, in turn, helps us design more streamlined and energy-efficient bicycles, thereby improving riding speed and efficiency.
Leveraging years of CFD expertise gained in F1 and motorsports, and solving the most challenging engineering problems to provide customers with super-accelerated solutions, design engineers at Vorteq, a company called TotalSim, have set their sights on creating the world's fastest bicycle.
The first phase of the project required the digital capture of a series of professional racing bikes in high-resolution 3D. After scanning, these 3D models of the bikes would be used for cutting-edge CFD analysis, combined with the latest wind tunnel testing and research, including analysis of the cyclists' (bike owners') own riding habits. All of this would then be integrated to create the final aerodynamic racing bike, the Vorteq WX-R .
Vorteq measurement engineers explained how they perform the scans:
1. "We scanned a range of bicycles to obtain accurate digital models, then compared them in our CFD system to see what the differences in resistance were, 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 bicycles and incorporate them into a single design."
2. "At the same time, during our design process, we collaborated with our SSEH Sports R&D partners to analyze the riders of these bikes to understand how they actively generate power and how this affects the entire bike. This yielded a wealth of invaluable data, a secret factor in designing bikes that can cut off the competition."
How does 3D scanning help during the mid-stage development process?
Engineers placed each rider's bicycle into a fixed clamp and then applied varying degrees of load to the crank area, adding some bending to the crank to observe the extent of frame flex. This continued until peak power was generated to reproduce the torque passing through the pedals, crank, and wheel axle. The bicycle frame was then precisely captured during this process using a 3D scanner , and deviation maps were generated from these scans, showing how and where the frame flexed.
3D scanning greatly simplifies engineers' workflows.
"I imported the scanned file into the post-processing software Artec Studio. Bicycle scanning is very quick. First, I did a simple , rough check to make sure everything looked perfect. Then, I used the eraser tool to delete any unwanted data in the scan. Finally, I performed global registration using the default settings, and the 3D model was already perfect."
The next key step will be 'sharpening and blending' to handle the components and rigid structures. Sharpening and blending preserves all the complex geometric details of the bicycle model we need. Then, it will be exported as an OBJ file to Geomagic Wrap to convert the 3D data file into a refined 3D model. After some additional design steps, the generated 3D model will be sent to a CFD system .
What is sharpening fusion? "
A special technique is used to merge different 3D scanned images or models together, making them appear clearer and more detailed. It's like combining several photographs into a better composite image, allowing us to see the shape and texture of objects more clearly and thus better understand what they look like.
After the research and development phase, in order to turn their ideas into reality, Vorteq partnered with British bicycle manufacturer Worx, which had previously built its own racing bikes, but not one like the Vorteq WX-R.
The Vorteq WX-R has already been used in competitions and is planned for the Tokyo Olympics. At the UCI World Track Cycling Championships, its full gear contributed two medals, three lifetime bests, two national records, and a new Asian record.
"When looking for a professional handheld 3D scanner , it must meet all requirements for accuracy, capture speed, and be designed to capture medium-sized objects with stunning colors. In our experience, a powerful scanner can completely capture a professional race car in 15 to 30 minutes."
[Related Product Recommendations]
1. Geomagic Control X 3D Automated Inspection Software
● Offers innovative new measurement and testing tools, workflow-driven planning processes, and step-by-step testing capabilities. ● Applicable to point clouds and probes, data is automatically generated into easily interpretable deviation color maps, and your products are automatically analyzed in detail.
● Provides a full range of intuitive measurement, dimensional, and tolerance tools, automatically detects geometric features, provides instant deviation tools, or performs iterative alignment calculations. ● Utilizes the automation capabilities of the Python programming language to customize environmental variables and inspection processes to meet company needs.
2. Geomagic Design X 3D Reverse Engineering Software
● Seamlessly connects to mainstream CAD software, including SOLIDWORKS®, Siemens NX®, Autodesk Inventor®, and PTC Creo®.
● Capable of processing over one billion point cloud data points, possessing a complete set of data processing functions. ● Converts 3D scanned data into high-quality feature-based CAD digital models. ● Similar to CAD software, easy to learn and use.
● Offers innovative new measurement and testing tools, workflow-driven planning processes, and step-by-step testing capabilities. ● Applicable to point clouds and probes, data is automatically generated into easily interpretable deviation color maps, and your products are automatically analyzed in detail.
● Provides a full range of intuitive measurement, dimensional, and tolerance tools, automatically detects geometric features, provides instant deviation tools, or performs iterative alignment calculations. ● Utilizes the automation capabilities of the Python programming language to customize environmental variables and inspection processes to meet company needs.
2. Geomagic Design X 3D Reverse Engineering Software
● Seamlessly connects to mainstream CAD software, including SOLIDWORKS®, Siemens NX®, Autodesk Inventor®, and PTC Creo®.
● Capable of processing over one billion point cloud data points, possessing a complete set of data processing functions. ● Converts 3D scanned data into high-quality feature-based CAD digital models. ● Similar to CAD software, easy to learn and use.
Did you discover any new business insights into the product/project after reading this? Or are you also looking at comparisons of 3D scanners?
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