CRP USA, a number one US-based 3D printing firm, has collaborated with USA Bobsled/Skeleton (USABS) to fabricate cutting-edge, race-ready 3D printed bobsled components – leveraging the modern Windform household of high-performance supplies.
Following the officialization of the know-how partnership, CRP USA has performed an important function in advancing Winter Olympics athletes’ efficiency by way of the creation of purposeful, stress-resistant, and versatile 3D printed elements for the USABS’s bobsled. These components, together with push handles, hand grips, and seats, have been pivotal in optimizing acceleration, minimizing forces, and guaranteeing enhanced efficiency throughout races. All these components are manufactured utilizing Windform supplies – push handles utilizing Windform SP, and hand grips and seats utilizing Windform XT 2.0.
Windform XT 2.0 and Windform SP are two Carbon fiber-filled composites from the Windform TOP-LINE vary of supplies for skilled 3D printing – Selective Laser Sintering – created by the Italy-based firm CRP Expertise.
The partnership between CRP USA and USABS aligns with the continued mission initiated by USABS to develop new bobsleds for the upcoming Olympic Winter Video games in 2026. All elements are made within the USA by way of the collaborative efforts of assorted companions taking part within the Made-in-USA mission.
CRP USA was launched to USABS by considered one of their technical companions, a neighborhood firm that focuses on carbon fiber merchandise. Since then, the CRP USA workforce of consultants and the USABS workforce had a number of conferences which resulted in a joint effort from each events to find out the appropriate supplies for his or her elements.
“The large benefit of 3D printing for the USA Bobsled/Skeleton workforce is that no molds must be made, so an enormous period of time is saved and the prices stay a lot decrease. To not point out a a lot sooner supply of the components as a result of no mould is required. The 3D course of additionally has many benefits as a result of extra complicated components may be made,” mentioned Marc van den Berg, Expertise and Gear Lead for USABS.
With out the appropriate supplies, using 3D printing know-how is just not the appropriate resolution for most of the initiatives. Nonetheless, this was not the case right here due to CRP’s Windform supplies. “Complying with the rules, by way of shapes and dimensions was the primary constraint,” mentioned van den Berg, including that one other crucial issue was the stress resistance. “In the course of the begin of the races, there’s giant forces on the bobsled. Additionally, bobsled crashes should be thought-about. For these causes, the development supplies need to be versatile and robust, to keep away from components breakage.”
The manufacture of push handles is a superb instance of the effectivity of the 3D printing course of mixed with the appropriate building materials, particularly when supported by expert technical workers who’re attentive to the shopper’s wants. “The USABS workforce wanted to simply produce the push handles, as well as, to customise the handles primarily based on every athlete and simply change them out,” mentioned Nathanael Baker, Senior Mission Coordinator for CRP USA.
For these particular elements, the CRP USA’s analysis led to the identification of Windform SP as probably the most appropriate building materials for its traits of resistance to shock, vibrations, and deformation (Density 68 °F: 1.106 g/cc, Density 20 °C: 1,106 g/cc; Melting Level: 380 °F, Melting Level: 193,3 °C; HDT 1.82 Mpa: 368 °F, HDT 1.82 Mpa: 186,5 °C; Tensile Power: 11000 psi, Tensile Power: 76,10 Mpa; Elongation at Break: 11.38% simply to quote some properties).
As quickly because the handles have been 3D printed, CRP USA shipped them to USABS, receiving reward for the velocity of producing and supply. Marc van den Berg and the USABS workforce have been thus capable of examine, check, and modify the components in keeping with their wants in report time.
“By avoiding the development of high-priced molds, we have been capable of shortly perform a number of checks utilizing barely totally different shapes primarily based on the wants that arose every now and then. The velocity of execution and supply by CRP USA allowed us to check the push handles to judge their resistance to emphasize and ergonomics, finishing up the mandatory iterations till we achieved the optimum consequence for us,” mentioned van den Berg. “We don’t have an official check program – we assemble the components and use them in a race. And so we did with the 3D printed components in Windform: Which means the seat, hand grip, and rear push deal with have been instantly examined in an actual race!”
“The most important requirement of the rear push levers is that they have to stay intact if the bobsled crashes, and that’s what occurred on this race, the bobsled crashed and the handles weren’t damaged!” mentioned van den Berg, including that the workforce was impressed by the efficiency of the 3D printed bobsled push handles. “The ultimate outcomes have been excellent – quick supply and infinite design chance. Hopefully, we are able to 3D print extra components sooner or later, even perhaps an entire bobsled!”
USA Bobsled/Skeleton is the nationwide governing physique for the sports activities of bobsled and skeleton racing in the USA. Primarily based in Lake Placid, NY, USA Bobsled/Skeleton oversees the event and coaching of American athletes in any respect ranges of competitors, from grassroots applications to the nationwide workforce.
The 3D printed components in Windform made their official debut on the IBSF North American Cup (NAC) – from the fifteenth to the nineteenth November 2023 – with wonderful outcomes: the USABS workforce received 2-man bobsleigh, Girls’s monobob, 2-woman bobsleigh, and 4-man bobsleigh.
