[3D Printing] BCN3D Printed Train Pod Wins Hyperloop Competition!

【3D Printing Application】BCN3D Printed Train Wins Hyperloop Pod Competition!

Hyperloop CHF used the BCN3D Epsilon W50 in the 2021 Valencia Hyperloop Competition to quickly and effectively 3D print molds and various end-use parts from different materials, creating a high-speed subsonic train prototype that even won the Hyperloop Pod Competition!

Inspired by Elon Musk, the international Hyperloop Pod Competition aims to create the fifth mode of transportation, allowing talented university students from around the world to unleash their creativity. One of the notable teams was Hyperloop CHF from the CHF Association in Madrid, who used the BCN3D Epsilon W50 and BCN3D materials to form and manufacture end-use parts, creating a unique streamlined pod prototype.

Goals of the Hyperloop Pod Competition

The Hyperloop competition is based on building a blueprint for a hyper-speed train that will change the way we travel in the future. Essentially, passengers sit in a protected capsule, enjoying a luxurious ride on a floating track, reaching their destinations at unprecedented speeds.
This was the Hyperloop CHF team's first time participating in the competition. They had a budget of only 100,000 Euros to complete the design and functional prototype, which included everything from the shell to the internal mechanics. They built a "hypertrack" to test their prototype, preventing any friction and ensuring it operated as expected.

3D Printing Accelerates Production Process

The students needed a local and professional 3D printer, and BCN3D reseller Sicnova proposed the BCN3D Epsilon W50 to them. Its large size and versatility perfectly met their needs. The ecosystem between programming and 3D printing technology was easy to implement, faster, and more efficient, thus facilitating their workflow. Saving time and money gave them more design freedom, which also became an advantage for Hyperloop CHF. Hyperloop CHF's subsonic high-speed train prototype measures 1.24 meters, with dimensions of 2x1x1 meters. Since it needs to fly at high speeds, ensuring the safety of the battery pack is important. Hyperloop CHF experimented with various materials with BCN3D and Sicnova to see which properties could advance their prototype, concluding that the high-temperature resistance of ABS delivered the best performance.

The 3D printed end-use parts were also very important for system stability. The wheels were printed with TPU, capable of withstanding high temperatures and forces. The brackets were made of carbon fiber, making the support system sturdy and reliable. The shell molds were also indirectly 3D printed. During rigorous testing on the hypertrack, the team found that PLA maintained its performance at speeds up to 120 km/h and was easy to print. Each large piece required 16 hours of printing, so the large size advantage of the BCN3D Epsilon W50 came in handy! The parts were merged, sanded, painted, and then formed into the molds for the carbon fiber shell, while keeping the shell as smooth and streamlined as possible.

With the 3D printed parts installed and tested, the team focused on refining the propulsion system and LC model during the competition countdown. Only 4 out of 11 teams passed all tests, and as the only team from a vocational training center, it was an impressive feat! Their next step is to improve the propulsion system and casing to achieve a target of 550 kilometers per hour.

This valuable learning opportunity has equipped students with knowledge of 3D printing design and production, signaling a potential wave of disruption in Industry 4.0!

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