Scale Motorcycle Engines: Design, Production & Deployment
Scale Motorcycle Engines: Design, Production & Deployment
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The big idea: I started this project wanting to reproduce a physical model of the engine in my motorcycle: an inline twin from my Royal Enfield Continental GT. Specifically, I wanted a model with working internals to demonstrate the reciprocal motion and firing pattern of the engine correctly. Ultimately, this project evolved into a deep dive into surface modeling within SolidWorks, and designing around the thermal contraction of PLA as I tried to manufacture these components: culminating in my contracting of a manufacturing partner, Jialichuang JLC (HK) to commission a production run of my engines in LEDO 6060 Resin for sale on my website, www.PocketPistons.bigcartel.com
The big idea: I started this project wanting to reproduce a physical model of the engine in my motorcycle: an inline twin from my Royal Enfield Continental GT. Specifically, I wanted a model with working internals to demonstrate the reciprocal motion and firing pattern of the engine correctly. Ultimately, this project evolved into a deep dive into surface modeling within SolidWorks, and designing around the thermal contraction of PLA as I tried to manufacture these components: culminating in my contracting of a manufacturing partner, Jialichuang JLC (HK) to commission a production run of my engines in LEDO 6060 Resin for sale on my website, www.PocketPistons.bigcartel.com
 Engineering Challenges: My models were designed in SolidWorks and Onshape CAD Programs, and were about 5x5x5 cm in size. I initially printed prototypes on my Creality 3D Printer using a 0.2mm nozzle, which limited dimensional accuracy. I had to account for the contraction of concave part features as the part cooled, and the expansion of convex features due to factors associated with the 3D Printer and the slicer software used to control it.
I had to modify my parts for manufacturability: the stereolithography (resin 3d printing) process used by JLC (my production partner) cannot reliably create parts with walls thinner than 0.5mm, or holes larger than 0.9mm. I also optimized for production volume by building parts trees that let me print 10 copies of a component in the same production batch.
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