JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 31

The Energica dashboard reinvented through professional 3D printing and composite materials

Fig. 2: The second dashboard prototype made with Windform® LX 3.0 (painted) (front and back)

Fig. 1: The first prototype of the Windform® LX 3.0
dashboard (front and back)

Fig. 3: The third dashboard prototype (hybrid version:
plastic injection upper part, Windform® LX 3.0 lower
part) (front and back)

First prototype
The shell was made in two separate parts.
Energica's suppliers of traditional technology
(mould makers) would have taken roughly
five months to prepare the prototype
moulds. Thanks to CRP Technology and
the Windform® composite materials, the
prototype was received in two days.
The next phase involved assembling electronic components and securing them with
mastic/glue. No difficulties or problems
were found during this phase.
The Windform® prototype was then returned
to Energica, which mounted it directly on the
bike (the holder for the bike can be seen in
Figure 1) and tested it on the road. In extreme
stress conditions, the prototype was able to
protect sophisticated electronic components
thanks to the construction material used. In
fact, this non-conductive material is ideal for
producing resistant end use parts and end
applications, which can withstand vibrations,
impacts, and multiple weather conditions.
Second prototype
The second prototype, thanks to the material's features, was painted in order to conduct

colour tests.
Third prototype
The third prototype is a hybrid version that
enabled the Energica staff and the mould
makers to conduct precise assembly tests.
This model features a lower part made by
3D printing using Windform® LX 3.0 and an
upper part produced by plastic injection.
The tests gave positive results and the
Energica engineers were satisfied. The two
parts were assembled without encountering
any problems. The plastic injection tolerances calculated are the same as those of the
Windform® composite material used.
Creation of the finished product using
traditional injection moulding technology
Once the Energica team's project was
approved, the mould makers developed the
mould for industrial production. Professional
3D printing technology and composite
materials enabled the team to shorten
product development times, and to continue
testing the component/prototype directly
on the motorbike. The functional dashboard
prototypes were used for roughly six months
and subjected to every kind of stress during
the test rides.
Thanks to the 3D-printed Windform® prototypes, the team was able to work with the
mould makers in a new way. These functional
components, which are much more than
just aesthetic prototypes, made it possible
to examine the application and make some
improvements for the final mould, therefore
saving time and money. When the team gave
the authorization to proceed with injection
moulding, they knew that the parts would
come out perfect and ready to be used.

Fig. 4: The three dashboard prototypes, from left to right: the first one made of Windform®,
the second one painted, and the "hybrid" one

N°121 May - June 2018

More information:
www.crptechnology.com
www.crp-group.com.

/ jec composites magazine

31


http://www.crptechnology.com http://www.crp-group.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #121 - May 2018

Cover
Edito
Opinion: Lighter, faster, smarter
Contents
NEWS
In brief
JEC World 2018 Report
JEC World 2018 gathered the whole composites industry in Paris
JEC innovation Awards Winners 2018
Startup Booster - A springboard for innovative talents
Injection - lnjection moulders who have made bioplastics work
Agenda
BUSINESS
Acquisition - Huntsman acquires Nanocomp Technologies
Simulation - "We want to bring the story of composites to the end user in a different way"
Trends - Overview of the North Amaerican composites market
MANUFACTURING
Additive manufacturing - The Energica dashboard reinvinted through professional 3D printing and composite materials
Prototyping - Injection moulding: running tests earlier with 3D printing
Mass-production - Fast RTM: a techincally and economically optimised solution
Covers - Opportunities for composite profiles in the residential housing market
SOLUTIONS
Building - CompoHouse, the demonstration building made of composites
Construction - Textile concrete makes thin, large-sized curtain walls possible
In the world
TECHNOLOGY
Multi-material - High-confidence performance predictions for hybrid thermoplastic composite applications
Experimental techniques - 3D tectile-reinforced composites: from manufacturing to structural design
Index
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JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Cover
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 2
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Edito
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Opinion: Lighter, faster, smarter
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 5
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Contents
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 7
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - In brief
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 9
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - JEC innovation Awards Winners 2018
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 11
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 12
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 13
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 14
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 15
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 16
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 17
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 18
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 19
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Startup Booster - A springboard for innovative talents
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Agenda
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 22
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 23
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Acquisition - Huntsman acquires Nanocomp Technologies
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 25
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Simulation - "We want to bring the story of composites to the end user in a different way"
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 27
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Trends - Overview of the North Amaerican composites market
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 29
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Additive manufacturing - The Energica dashboard reinvinted through professional 3D printing and composite materials
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 31
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Prototyping - Injection moulding: running tests earlier with 3D printing
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 33
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Mass-production - Fast RTM: a techincally and economically optimised solution
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 35
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 36
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 37
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 38
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 39
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 40
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 41
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 42
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 43
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 44
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 45
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 46
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 47
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Covers - Opportunities for composite profiles in the residential housing market
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 49
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 50
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 51
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 52
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 53
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 54
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 55
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Building - CompoHouse, the demonstration building made of composites
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 57
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 58
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Construction - Textile concrete makes thin, large-sized curtain walls possible
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - In the world
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 61
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Multi-material - High-confidence performance predictions for hybrid thermoplastic composite applications
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 63
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 64
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 65
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 66
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Experimental techniques - 3D tectile-reinforced composites: from manufacturing to structural design
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 68
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 69
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 71
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 72
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