
Airbus aerospace’s latest project is a demonstration of how 3D printing can be used to make complex, high-strength shapes, but it isn’t built in their usual form factor. Instead, it’s an electric motorcycle with the power-to-weight ratio of a sports car. The frame, made out of 3D-printed, aircraft-grade aluminum alloy that goes by the brand name Scalmalloy, enables the entire thing to weigh just 77 pounds and accelerate from a standstill to 45 km/h in 3 seconds. By itself, the frame weighs just 13 pounds.
The organic-looking pipes that make up the frame were made possible by combining thousands of 60 micron layers in a metallic powder bed. This was done using “bionic algorithms,” in which the algorithm governing the printer was instructed to follow pathways based on natural growth processes and biological patterns. The frame parts are hollow, allowing pipes, cables, and screw-on parts to be added in and around the printed portions.
“The complex and branched hollow structure couldn’t have been produced using conventional production technologies such as milling or welding,” said Joachim Zettler, CEO of Airbus APWorks GmbH. “Advances in additive layer manufacturing have allowed us to realize the bionic design we envisioned for the motorcycle without having to make any major changes. With these technologies, the limitations facing conventional manufacturing disappear.”
Only 50 of these motorbikes will be available to the public, but they are available for pre-order now. A deposit of €2,000 ($2,229) goes toward the retail price of €50,000 ($55,747).