Lighter, smaller, more agile: That was the mandate that Machineart Industrial Design followed for their BMW R1200GSM concept bike, which was designed used Direct Digital Manufacturing techniques:

GSM body parts were modeled in Alias Studio Tools and SolidWorks 3D CAD software, and produced in ABS-M30 plastic directly from 3D CAD data using two Fortus 3D Production Systems from Stratasys.

Fortus systems use FDM, the leading technology in 3D printing and 3D production. Fortus systems eliminate the need to make tooling to mold plastic parts and allow easy revision and customization from one set of parts to the next.

A total of 16 parts were made in the large Fortus 400mc and Fortus 900mc machines, including two parts that served as the female halves of molds used to cast polyurethane foam seat cushions--an example of direct digital manufacturing of manufacturing tools.

The lower cowl near the exhaust pipes is produced from PPSF (polyphenylsulfone) a heat-resistant material option for the FDM process. This process enabled making ABS-M30 body parts in less than a month, saving many months of time over traditional prototyping methods.

To see photos of the design process, click here.