From CAD to show model in 3 weeks with CIDEAS

Jul 25, 2019

With a very short lead time, Livemap utilised CIDEAS to bring their concept to life and wow crowds at CES 2019 with their freshly designed HUD Navigation smart motorcycle helmet.

CIDEAS 3D printing motorcycle helmet

Livemap is in the process of developing the first motorcycle helmet with a permanent built in HUD that meets crash safety standards. In a fast-paced market, they set their sites to reveal their latest design at CES 2019 in Las Vegas, Nevada. Once their industrial designers completed the finishing touches, they turned to CIDEAS to make their vision into a physical, wearable show model.

CIDEAS 3D printing motorcycle helmet_2Dan Williams, Head Engineer at CIDEAS, determined the best approach to produce a model that not only looked like a production helmet, but also had the functionality of one as well. This included: adjustable vents, camera mounts, an articulating adjustable mounting hinge and a fully polished clear 3D printed visor. As it turns out, many of the design components needed to be tested for form fit and function, these tests were performed prior to assembly in order to validate the design and make adjustments as needed.

Overall, approximately 40 3D printed parts were used to create the final helmet. The majority of the parts were created on an SLA system utilising Accura 25 (a general purpose material), due to its ability to create accurate models with good impact strength, good heat deflection and excellent surface finishes. SLA (Accura ClearVue) was used to produce the clear visor. The smallest and functional components were a mix between SLA, SLS (Nylon 12) and DLS (RPU70). Materials were chosen to meet the functionality needs of the gears, fixtures, connectors, and smaller flexible parts. 

Each of the parts were sanded, primed and painted using a 2-stage automotive grade, color matched paint. The vector logos and markings were converted into PMS color matched decals and applied before the final clear coat, which protects them from being scuffed or scratched. The SLA clear visor was hand sanded to a near mirror finish, then protected with a UV resistant automotive clear coat (color tints may also be applied to clear parts when needed). Actual hardware was sourced for assembly and gaskets, while the foam liner was modified from an existing helmet.

CIDEAS Inc sets the bar for Custom and Complex Solutions

CIDEAS is a full-service 3D printing and Additive Manufacturing Center. Utilising the most current 3D printing: equipment, materials and software, CIDEAS’ dedicated team has over 250 years of combined experience within the Additive Manufacturing and 3D printing industry.

Since 1988, CIDEAS’ Project Managers, Operators and Finishers treat each job with care and consideration in order to meet the needs and budget for each of the thousands of projects that are produced annually within its state of the art facility located in Crystal Lake IL. Lead times are typically 1 to 2 days for most 3D printed parts. Finishing lead-times vary, due to complexity and technology.

If you would like to discuss a current or future project with a CIDEAS representative, please contact us today at +1-847-639-1000 or visit www.buildparts.com

The process – from CAD to show model in 3 weeks

CIDEAS 3D printing motorcycle helmet_3

 

SLA was used to produce the helmet shell. Accura 25 resin was chosen due to its accuracy, durability and heat deflection. SLA parts tend to sand easier than traditional thermal plastics, which in turn reduces finishing time.

 

CIDEAS 3D printing motorcycle helmet_4

 

During the finishing stage, an action camera was installed, as well as the HUD projector and additional electronics for design verification and testing.

 

 

CIDEAS 3D printing motorcycle helmet_5

 

Upon completion, helmet fit checks were initiated to ensure proper foam and gasket installation. Electronics were double checked for proper fit, as well as the operation of vents and the visor.

 

 

CIDEAS 3D printing motorcycle helmet_6

 

Here the final Livemap helmet gets a final inspection prior to the client taking delivery.

End

The post From CAD to show model in 3 weeks with CIDEAS appeared first on Racecar Engineering.


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