[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 3D scanning case studies from abroad, including: optimizing food production lines, 3D scanning and printing prosthetics, industrialforge mold repair... This time, a bicycle manufacturer has successfully used scanning technology to push their product design culmination to the World Track Cycling Championships. They were specifically designed for the "2021 Tokyo Olympics" project and have received full accreditation from the "Union Cycliste Internationale (UCI)."
This demonstrates that if 3D scanning technology is mastered and combined with product development insights, the business opportunities it brings far exceed imagination. Let's see how they transformed the ultra-fast WX-R bicycle design into a real product!
Challenge
A sports R&D company, Vorteq, needed to digitally capture a series of professional racing bicycles in high-resolution 3D for the purpose of creating highly aerodynamic competitive bicycles.
Solution
Artec Leo, Artec Space Spider, Artec Studio, Geomagic Wrap
Results
Using a professional handheld 3D scanner, 3D models of multiple racing bicycles were captured. These precise 3D models, with accurate geometries of the bicycle frames and components, were combined with 3D data to design an exceptional bicycle.
In the world of professional and Olympic cycling, air resistance truly is a drag. But now, through the use of the latest handheld 3D scanning technology combined with cutting-edge CFD (Computational Fluid Dynamics) analysis, CAD expertise, and design thinking, UK-based company Vorteq, in collaboration with WX-R engineers, has created a bicycle that can slice through the air, and it's already making waves in the cycling industry.
Vorteq WX-R Competition Bicycle (Source: Courtesy of Vorteq)
In high-speed triathlon races, using an aerodynamic bicycle compared to a regular race bicycle can mean crossing the finish line minutes earlier in a 5-hour cycling stage. But what about an even faster bicycle? One that can even outperform the most powerful teams?
For decades, racing bicycle manufacturers have strived to make their mechanical designs the preferred race bicycles on the road, but for the most part, their designs have been based on those of their competitors. Wind tunnel testing and CFD testing are occasionally used. However, a crucial aspect has largely been overlooked: the speed equation, the riders themselves, their bicycles, and biomechanics. Considering more aspects than competitors is an excellent strategy to beat them.
“ What is CFD? ”
A type of computational fluid dynamics that uses computer simulations and analysis to understand the behavior of fluids (such as gases or liquids) under different conditions.
“ 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.
Leveraging years of CFD expertise gained from working in F1 and motorsport, solving the toughest engineering challenges to provide super-accelerated solutions for 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 bicycles in high-resolution 3D. After scanning, the 3D models of these 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 bicycle owners). Afterwards, everything would be integrated to create the ultimate aerodynamic racing bicycle, the Vorteq WX-R.
Vorteq's measurement engineers explained how they performed the scans:
1. "We scanned a series of bikes to get accurate digital models, which we then compared 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, our sports R&D peers, to analyze the riders of these bikes to understand how they actively generate power and how this affects the entire bike. A lot of very valuable data was obtained here, which is a secret factor to cut down competitors when designing bikes."
How did 3D scanning help in the interim development process?
Engineers placed each rider's bicycle in a fixed jig, then applied varying degrees 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 reproduce the torque through the pedals, crank, and through the wheel axle. Then, a 3D scanner was used to accurately capture the bicycle's frame during this process, and deviation maps were generated from these scans, showing how and where the frame bent.
3D scanning simplified the engineer's workflow
"After importing the scan files into the post-processing software Artec Studio, bicycle scanning is very fast. First, a quick rough check of the prototype ensures everything looks perfect. Then, use the eraser tool to delete any unwanted data in the scan. After that, perform a global registration with default settings, and the 3D model is already very good."
The next step will focus on 'sharpened fusion' to process components and rigid structures. Sharpened fusion preserves all the complex geometric details of the bicycle model that we need. Then, it will be exported as an OBJ file to Geomagic Wrap to transform the 3D data file into a beautiful 3D model. After some additional design steps, the generated 3D model will be sent to the CFD system."
“ What is Sharpened Fusion? ”
It uses a special technique to combine different 3D scan images or models, making them appear clearer and richer in detail. It's like combining several photos into one better composite picture, allowing us to see the object's shape and texture more clearly and understand its appearance better.
Following the R&D phase, to bring their ideas to life, Vorteq collaborated with UK bicycle manufacturer Worx, who had previously built their own race bikes, but none like the Vorteq WX-R.
The Vorteq WX-R has already competed in races and is planned to participate in the Tokyo Olympics. At the UCI Track Cycling World Championships, its full kit contributed to two medals, 3 personal bests, 2 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 in stunning color. In our experience, a powerful scanner can fully capture a professional racing bicycle in 15-30 minutes."
[Related Product Recommendations]
1. Geomagic Control X 3D Automated Inspection Software
● Provides new creative metrology and inspection tools, workflow-driven planning processes, 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 products in detail.
● Provides comprehensive intuitive measurement, dimensioning, and tolerancing tools, automatic detection of geometric features, real-time deviation tools, or iterative alignment.
● Uses Python programming language for automation, setting environment 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®.
● Can process over one billion point cloud data points and has a complete set of data processing functions.
● Transforms 3D scan data into high-quality feature-based CAD digital models.
● Easy to learn and use, similar to CAD software.
● Provides new creative metrology and inspection tools, workflow-driven planning processes, 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 products in detail.
● Provides comprehensive intuitive measurement, dimensioning, and tolerancing tools, automatic detection of geometric features, real-time deviation tools, or iterative alignment.
● Uses Python programming language for automation, setting environment 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®.
● Can process over one billion point cloud data points and has a complete set of data processing functions.
● Transforms 3D scan data into high-quality feature-based CAD digital models.
● Easy to learn and use, similar to CAD software.
Have you discovered new business insights for your product range after reading this? Or are you also considering comparing 3D scanners?
▶Learn more related articles👉[3D Scanning Knowledge] What is 3D Scanning Accuracy? - SHINING 3D Scanner Purchase Guide
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