Applying a Combination of Cutting-Edge Industry 4.0 Processes towards Fabricating a Customized Component

Abstract

3D scanning, 3D printing, and CAD design software are considered important tools in Industry 4.0 product development processes. Each one of them has seen widespread use in a variety of scientific and commercial fields. This work aims to depict the added value of their combined use in a proposed workflow where a customized product needs to be developed. More specifically, the geometry of an existing physical item’s geometry needs to be defined in order to fabricate and seamlessly integrate an additional component. In this instance, a 3D scanning technique was used to digitize an e-bike’s frame geometry. This was essential for creating a peripheral component (in this case, a rear rack) that would be integrated into the frame of the bicycle. In lieu of just developing a tail rack from scratch, a CAD generative design process was chosen in order to produce a design that favored both light weight and optimal mechanical behaviors. FDM 3D printing was utilized to build the final design using ABS-CF10 materials, which, although being a thermoplastic ABS-based material, was introduced as a metal replacement for lighter and more ergonomic component production. Consequently, the component was manufactured in this manner and successfully mounted onto the frame of the e-bike. The proposed process is not limited to the manufacturing of this component, but may be used in the future for the fabrication of additional peripheral components and tooling.