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Miata 3d printed intake


This 3D Printed Mazda Miata Engine Modification Adds Quick Power Without Breaking the Bank - 3DPrint.com

There is much evidence about how functional and convenient 3D printing can be. Businesses and individuals constantly report that they are using the technology to reproduce or improve small to large replacement parts, making their repair time much quicker. Examples I have written about before range from huge companies like Caterpillar Inc., which uses 3D printing to save time on the assembly line, to individuals like Frankie Flood, who used 3D printing to sand cast a wing nut he could no longer order. Given what a significant financial investment automobiles are, you can imagine how convenient it can be to be able to 3D print replacement car parts. But also consider 3D printed engine modifications that add original “aftermarket” parts you can successfully 3D print — like this cold air intake for an older model Mazda Miata that will power up your engine right quick!

This example of a new engine part print job was executed by a Reddit user called “TheRealSpaceTrout,” who took the original design from “hard surface freelance artist” Alec Moody. Moody has worked in the game industry for 14 years, and he co-owns handplane, which develops tools for video game artists. But he also designs 3D printable models, including his “aftermarket” cold air intake system for Miatas made between 1994 and 1997. Cold air intakes are engine modifications, which means they aren’t included in the original vehicle. This modification moves the engine’s air filter outside so that cooler denser air is sucked into the engine; this brings more oxygen, and hence more power, into the combustion chamber.

Here, Moody explains the design, which is open source with available files:

“The design started with a urethane expanding foam pour to capture the availible negative space, that was 3d scanned and I have made about a dozen design iterations over the course of 9 months. I was careful in the design to make smooth transitions between shapes and keep a very consistent cross sectional area at every point of the duct.”

When TheRealSpaceTrout 3D printed the intake modification, he used ABS plastic, acetone vapor bath, and XTC-3D coating. A hole cut into a K&N filter allows for air to enter the tube.

Moody also reports he has only printed the part in ABS, because he states that PLA will “almost definitely melt or deform.” Moody prints everything in multiple sections, and bonds them with ABS cement — “MEK solvent with ABS filler” — which he found in the Home Depot plumbing section.

If you have a Mazda Miata, or know someone who does and would like to add some 3D printed power to the car, you can check out this cold air intake, which proves to be more cost effective and easier to install than other car engine modifications. Discuss in the 3D Printed Cold Air Intake forum over at 3DPB.com.

 

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Tagged with: 3D printed automotive components • 3d printed automotive parts • 3d printed car parts • 3D printed cold air intake • 3d printed engine parts • Alec Moody • mazda miata • TheRealSpaceTrout

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Sharebot optimizes race bike design

The idea behind 3D printing is based on its technological features (such as customization and object reproducibility) that allow the development of innovative racing bike solutions. Motorcycle racing is a highly competitive field where even the smallest detail can affect the result and lead you to victory.

Andrea Pirazzini, founder and director of 3D service provider Help3D, has a passion for racing and competes in the Velocità CNV Motoasi Italian Championship for 100 octane pit bikes. According to Andrea (and we totally agree with him), The advantage of additive technologies is the ability to create unique shapes from technical materials - this is exactly what you need to work on prototypes and models of racing motorcycles.

Another great advantage of 3D printing, according to Andrea, is the variety of materials that can be used. The world of additive manufacturing is constantly evolving and there is a need to develop technical materials with advanced performance characteristics to create better and more efficient parts. That is why 3D printing can be applied to any manufacturing process, streamlining and streamlining prototyping.

Andrea has already used a Sharebot 3D printer to print plastic prototypes for racing bikes and has worked with the Quarto di Litro team at the University of Pavia on concept bike parts.

All parts were made on Sharebot Q and Sharebot 42 3D printers (modified version - Sharebot 43). For example, a multi-component fork assembly that was printed on the Sharebot 42 in just 20 hours using PLA plastic, or gaskets and links made from thermoplastic polyurethane (TPU). The choice of these elastic materials is due to the high load that they must withstand. The printed part was tested and no problems were found as a result.

One of the most interesting prototypes is a 1:1 printed pit bike body (23 hours of work). Thanks to 3D printing, Andrea Pirazzini was able to reproduce every technical and aerodynamic detail with the highest precision and resolution. He also created the air intake and spigot from high-strength polybutylene terephthalate (PBT).

3D printing and motorcycle racing: when every detail counts

MotoGp is ​​the world championship of road racing, the premier competition in its class. At an event of this caliber, every detail counts, and the bike's continuous optimization helps the rider lap a few precious tenths of a second faster.

We used to think that only a better motor is enough for more speed, but in reality it is not so simple. Over the last few years at MotoGp, motorcycles have been getting aerodynamic fenders on the front of the fairing: at first they were thought to be just a beautiful accessory, but over the years fenders have become the basis of motorcycle aerodynamics, especially because they increase downforce, and therefore traction on asphalt, and also reduce the resistance to movement during acceleration.

Drilling templates

In preparation for the next racing season, the famous Italian racing motorcycle manufacturer Aprilia, using Sharebot 3D printers and Help3D technical support, has developed drilling templates for the motorcycle front fairing. The 3D template models were created directly from the fairing CAD models and then printed using the Sharebot QXXL and Sharebot 42 printers. It should be noted that the shape of the wings (made of carbon fiber) is adapted to the fairing, so it is important that the holes in the body provide a snug fit at an ideal angle.

Footpeg mount

It's no secret that a motorcycle rider must sit like a glove. It's not just about a comfortable posture, but also about optimizing the rider's aerodynamics on the bike.

The kickstand plays a vital role in rider's riding position: it is more rearward and higher than in a road bike. If it is the wrong size, then the rider may feel discomfort, and in this position he will be uncomfortable.

Sharebot's 3D printers allowed the Aprilia Racing team to create a series of PLA footpeg mounts to see which model would work best for the team's riders. After analyzing different solutions and selecting the ideal model for each rider, the parts were made on a CNC milling machine.

With this solution, Aprilia has been able to reduce the design time and, above all, the production costs for each footpeg, while at the same time creating the optimal model for each rider.

Air intake

Engine performance is also very dependent on how and how efficiently it "breathes". Sizing an air intake for a MotoGp requires careful study of the flow and turbulence created within the design. The air intake uses lightweight and ultra-strong carbon fiber. The downside is that the part requires a mold to make: thin sheets of carbon fiber pre-impregnated with epoxy are placed in a mold and then placed in an autoclave to complete the catalysis process and eliminate air bubbles.

In preparation for the season, the Aprilia Racing team created a series of PLA gearbox prototypes on the Sharebot QXXL 3D printer. By simulating various adapters and reducers, the sports division technicians were able to test different volumes on the test rig, starting with just the air intake.

This approach made it possible to determine the optimal air intake geometry without the need to pre-mould and exfoliate the CFRP, thus saving time and money. The printed reducer can be tested on the bench, simply replacing one model with another, without removing the air intake each time. After determining the optimal geometry, one final mold was made to create the air intake.


Results

A summary of the 3D printing projects using Sharebot FDM printers that have optimized the design and aerodynamics of motorcycles for the MotoGp World Championship.