Electric bike exploits advanced prototyping for composite moulding
The award-winning GoCycle electrically assisted bicycle is cited as “the world’s lightest production two-wheeled electric vehicle.” It was developed partly using the Protomold process provided by Proto Labs, rapid injection moulding service with a UK facility at Telford.
The GoCycle is designed and produced by British company Karbon Kinetics Ltd (KKL). A Mark 2 version, currently in development, includes performance upgrades and is scheduled for a late 2011 launch.
The bike was designed to appeal to young, urban professionals and their families, with a view to combining portability, style and on-demand electric power to offer the rider the health benefits of cycling and, at the push of a button, a no-effort, emission-free run-around.
A high-powered electric motor is mounted in the cycle’s front hub. The Mark 2 will be quieter, smoother and have a more powerful gear drive, reports KKL, allowing the rider to quickly reach speeds of 25kph (16mph) and travel for up to 64km (40 miles) on a single charge of the new, lightweight lithium battery (double the range of the first generation and 1 kg lighter).
KKL was founded in 2002 by Richard Thorpe, with the aim of developing and commercialising light electric vehicles – from small city cars to electric motorcycles – starting with Gocycle which incorporates a pioneering injection-moulded magnesium alloy frame in history.
Thorpe commented: “We chose the best manufacturing options available from around the world. Proto Labs offered a unique service to our product designers that allowed our development process to proceed much faster. You just submit your three-dimensional CAD model to the ProtoQuote automatic quotation system, and you receive pricing, options and advice for improved ‘mouldability’ within hours.”
While the Gocycle’s frame is made using magnesium, the main mechanical parts such as the rear suspension unit are made using a specially formulated nylon filled with 60% of long glass-fibres. The expertise to injection mould this lightweight, strong material was provided by Protomold.
According to managing director John Tumelty, the company's senior engineers had not previously worked with a material incorporating such a high glass content in parts where the cosmetic surface finish demands were so high. For this reason, they were uncertain how well the material would flow during the injection moulding process.
Plastic Injection Molding Company - News
The data collected were entered into Protomold's in-house flow analysis software Protoflow, yielding a visual prognosis of the injection moulding process. Using this, the company's engineering team then tested the locations points where the plastic
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SMP, a division of Plastic Products Co. Inc., is owned by local entrepreneur Marlene Messin. SMP has been unable to expand its high-tech metal injection molding facility at its current 29000 square foot plant in Lindstrom. It needs a facility large
“We used to always default to 'We'll make it,' ” said Bruce Catoen, chief technology officer of the company, which builds injection moulding machinery used by global makers of plastic parts. “Now we say, 'Is there any place we can buy it before we make
The company's president, Tom Duffey, estimates that 100 to 150 students from nearby Germantown High School have visited the plant during that span, but only one of them has ended up being hired by the plastic injection molding firm.
Is Your Plastic Injection Molding Company Sustainable?
Did you know that waste could generate energy? Energy-from-waste technology is now available through companies like Specialty Waste Solutions, LLC, (SWS). In fact, The Rodon Group was one of the first molding facilities to be designated as a "Landfill-Free Facility" by SWS. This means all of The Rodon Group's waste gets processed into electricity. SWS generates enough electricity from waste to power tens of thousands of homes per day! See if you are working with a "landfill-free" facility. The most eco-friendly plastic injection molding companies employ state-of-the-art machinery to assist them in minimizing waste, transportation, and packaging. The Rodon Group was able to go from packing 750 parts to 4500 parts per box by implementing a robotic packing system. Now, 15,700 fewer boxes are being used and 13 less trailers are on the road. Additionally, plastic waste is eliminated from the molding process through the use of high-tech equipment that transports it to a grinder so that it can be re-used. A plastic injection molding company that thinks green is "landfill-free," and has the right certification, waste reduction, transportation and technology in place to minimize the impact on our planet. As a business owner, it’s your job to ask the right questions and make sure the company you work with is sustainable.
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