Reinforced Plastics d Volume xxx, Number xx d xxxx 2018
com
Carbon fiber 3D printing propels bike
development
Liz Nickels
Composites specialist Hexcel recently teamed up with a 3D printing manufacturer to develop a
lightweight commuter bike. Liz Nickels spoke to the companies to find out more.
Arevo, based in Silicon Valley, California, USA, is a startup com-
pany that specializes in 3D printing strong, lightweight compos-
ite parts for end use applications in high volume.
In recent years, Arevo has received funding of US$7 million
and US$12.5 million from investors led by investment firm Kho-
sla Ventures, while in June 2017 Arevo closed a strategic invest-
ment and technology development agreement with In-Q-Tel
(IQT), a non-profit strategic investor for the US intelligence com-
munity. The new financing was intended to help the company
build on its research and focus on the full-scale commercializa-
tion of its technology across a range of industries such as aero-
space, defense, transportation, automotive, consumer
electronics, sporting goods, medical, and oil and gas.
The company makes composite formulations that use a poly-
mer matrix reinforced with carbon nanotubes, carbon fiber and
glass fiber to help improve strength, stiffness, durability, wear
resistance, chemical resistance, thermal stability and electrostatic
discharge (ESD) properties. The 3D printed parts reportedly have
improved mechanical properties using Arevo’s software algo-
rithms that use additive finite element analysis. The company’s
software includes CAM software to convert CAD models to a
set of additive deposition instructions for the robot, a kinematics
simulator that interprets the deposition instructions, and a plat-
form which can interface with programming and simulation
software to ease tool path generation from CAD files.
Robotic printing
Along with providing new materials and design/build software,
Arevo has also developed a 3D printer that uses ‘free motion
robotics’ with the aim of making additive manufacturing (AM)
more flexible. While other 3D printers usually print in two
dimensions on a stacked horizontal plane, Arevo’s robotic arm
makes all axes available, potentially giving more design freedom.
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The machine consists of a standard commercially available
robot, composite deposition end-effector hardware and a soft-
ware suite. It is tailored to a small six-axis IRB 120 robot supplied
by robotics specialist ABB, though the scalable software could
support larger ABB robot models and sizes. The additive end-
effector hardware consists of a deposition head with thermal
management technology for processing carbon fiber reinforced
thermoplastics. The platform’s multi-axis toolpaths enable, for
the first time, production quality parts constructed with true
3D surfaces in variable orientations, Arevo says.
According to the company, the robotic additive manufactur-
ing (RAM) platform can help maximize size scalability and pro-
duction efficiency, and it also offers automation and secondary
process integration within manufacturing work cells. Depending
upon the size of the robot, the part build envelope is scalable
from 1000 mm3 to 8 m3.
‘We are excited to be the first to develop a robot based additive
manufacturing platform optimized for composite parts,’ said
Hemant Bheda, chairman and cofounder of Arevo. ‘Unencum-
bered by the constraints of conventional Cartesian systems, this
platform is the dawn of the additive manufacturing work cell for
the aerospace and defense factory-of-the-future.’
‘Arevo’s approach is a significant leap forward as it is truly 3D
printing rather than stacked 2D printing, which is what most of
us are accustomed to,’ said Vinod Khosla of Khosla Ventures.
‘Arevo is the company that can finally move 3D printing beyond
novelty applications and into a mainstream manufacturing
necessity with its unique nexus of software, robotics, and com-
posite materials.’
Innovative design
Recently, the company teamed up with Hexcel Corporation,
which makes carbon fiber reinforcements and resin systems, to
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 FEATURE Reinforced Plastics d Volume xx, Number xx d xxx 2018

produce what the companies say is the world’s first 3D-printed I spoke to Lyndon Smith, director of fibers at Hexcel, and
commuter bicycle, using Hexcel carbon fiber. The bicycle has a Hemant Bheda about the 3D printing bicycle.
new design created by Arevo in partnership with bicycle design-
ers StudioWest, which uses design software such as Solidworks
How could using 3D printing change bike design?
and Alias Studio to make rapid, flowing form development in
Smith: 3D printing increases the speed-to-market and design
photorealistic detail. The design involved the removal of a seat
freedom. Additive manufacturing offers the capability to add
stay between the seat and back wheel, adding strength and sim-
strength and complex design features where needed, with the
plicity, according to the companies.
ability to test finished components rapidly without the need
Hexcel is a manufacturer of HexTow carbon fiber, which suit-
for complex molds or tooling.
able for aerospace and industrial applications. The company is
also a leading carbon fiber supplier for US military applications.
Carbon fiber is stiffer, stronger, and lighter than other fibers What are the benefits of 3D printed CFRP over 3D printed
and is selected for its high strength, lightweight, superior stiff- metal?
FEATURE

ness, electrical conductivity, low thermal expansion, high ther- Smith: Carbon fiber has many benefits over its metal counter-
mal conductivity and corrosion resistance. Hexcel’s carbon parts that translate into 3D printing manufacturing as well. Car-
fiber is produced in a two-step proprietary continuous operation bon fiber is lighter than metal while still exhibiting the same, or
in which polyacrylonitrile (PAN) precursor undergoes a series of even greater strength. Within the cycling industry, the less
controlled processes including exposure to high temperature weight you have to move, the faster you can go to win the race.
changes, yielding high strength-to-weight and high stiffness-to-
weight properties through oxidation and carbonization. Surface
How does Arevo's version of 3D printing differ from other
treatment and sizing steps can help improve bonding and handle
techniques?
ability of the fiber.
Smith: There are many types of 3D printing processes that have
HexTow carbon fiber is used in Airbus A350 XWB, JSF, F18 E/
differing capabilities dependent on the part and size of compo-
F, A380, Eurofighter Typhoon, Global Express, Airbus A400M,
nent being manufactured. Arevo’s True 3D Printing is not
V22 Osprey, Boeing 787, and GEnx Engines. The fiber is available
restricted to an XYZ axis like conventional Cartesian-based addi-
in two states: continuous carbon fiber and chopped carbon fiber.
tive manufacturing equipment, but prints with a 6-axis system
Continuous fiber can be combined with all thermoset and ther-
allowing for superior strength and aesthetics. This technology
moplastic resin systems and is used for weaving, braiding, fila-
is suitable for many industrial, recreational and aerospace parts
ment winding applications, unidirectional tapes for ATL and
that are currently made with metals.
AFP processes and prepreg tow for fiber placement.
Chopped carbon fiber is used in compression and injection
molding compounds to produce machine parts, gears and chem- How does the robotic arm work?
ical valves. HexTow PAN-based carbon fiber is available in 1/4 Bheda: The robotic arm extends existing printing process from
inch chopped fiber lengths, sized for compatibility with various stacked horizontal layers deposition (2.5D) to deposit material
resin matrix systems and processes. The chopped product is on a 3D surface (True3D). True3D deposition is achieved with a
small, thin, rectangular flake, 1/4 inch long by 1/8 to 1/4 inch six-axis articulated robotic arm.
wide. The individual filaments are lightly held together by the
sizing and will break apart during subsequent processing.
What are the issues surrounding 3D printing onto fiber?
Bheda: 3D printing offers a number of benefits such as manu-
facturing complex shapes/structures not possible before, manu-
Improved strength
facturing on demand, lower cost due to elimination of
Arevo is making use of the bike to demonstrate its technology,
molds/tools, mass customization etc. However, until now there
which could be used to produce lightweight parts with improved
was no solution for 3D printing parts made completely from con-
strength for applications where designers want to make carbon
tinuous carbon fiber composites. Arevo technology enables 3D
fiber parts but are hesitant due to the high cost and labor-
printing of continuous carbon fiber composites with innovations
intensive process of making them.
in materials, process and software. Arevo process involves laser
‘We congratulate Arevo on this technological leap forward,’
based direct energy deposition technique that provides high
said Brett Schneider, Hexcel president, global fibers. ‘We’re
throughput rate and virtually void free parts (<1% void content).
excited to be part of the project and appreciate the trust they
Arevo software can optimize the fiber orientation in 3D space
have in our products. We look forward to continuing to be a sup-
based on part geometry and load conditions to get the highest
plier for many more projects like this one.’
strength to weight performance.
‘It was great to have Hexcel – a leader in advanced carbon fiber
– join this project with us,’ said Arevo CEO Jim Miller. ‘With
companies like Hexcel as partners, we are certain that we have What makes Hexcel's CF suitable for 3D printing?
the technology, team and tools in place to commercialize our Smith: Hexcel offers a wide range of unsized fibers for compa-
software and fabrication process to build high strength parts that nies in 3D printing. The lack of a sizing agent ensures there are
the manufacturing industry hasn’t been able to conceive and no adverse effects between the fiber and the resin chemistry,
construct before.’ enabling optimal properties for the part being designed.

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Reinforced Plastics d Volume xx, Number xx d xxxx 2018 FEATURE

How might reinforced plastic 3D printing affect fiber
development?
Smith: We will need to ensure that we provide the right tensile
and modulus performance in our fibers commensurate with true
carbon fiber parts design, but made with 3D printing rather than
typical layup manufacturing. We will need to work with the 3D
printing companies to select the right fiber for their desired per-
formance window.
How can the fiber be optimized for the process?
Smith: Our fibers are already optimized relative to form and
function and have no extraneous materials such as sizing to
therefore eliminate barriers to the 3D printer. The only other step
quickly produce custom bike frames, we’ll be able to meet the
increasing demand for eBikes at a fraction of the time, cost and
environmental impact of the standard bike production process.’
‘The development of the eBike has proven that we can 3D
print a new product when needed, at a low cost and localize
the manufacturing process – significantly cutting down on the
process and time it has taken historically to create bike frames,’
said Jim Miller.
Hexcel Corporation; www.hexcel.com
Arevo; www.arevoinc.com

FEATURE
we could take from this point would be to create a thermoplastic
sizing for our fibers, which we are not planning at this time.

Does Hexcel plan to move more into 3D printing?

Smith: Hexcel has been investing in the 3D printing segment
for a while now. In 2017 we acquired Oxford Performance Mate-
rials’ additive manufacturing technology for aerospace and
defense applications. Our current HexAM additive manufactur-
ing technology uses a selective laser sintering method of printing
which differs from Arevo’s method, and is already flight-qualified
The 3D printed bike, made using Hexcel carbon fiber.
on several different aerospace applications. We are actively
involved in 3D printing both in terms of fiber supply and parts
production.

What other parts can be printed in this way?

Bheda: Lightweight composite parts could replace metal parts
for aerospace, defense, transportation, consumer, consumer elec-
tronics, construction, oil and gas industries. The incorporation of
fibers provides up to 10 times strength-to-weight performance
when compared with just plastic parts.

Battery power
Arevo says that it is now moving beyond prototypes and has
secured financing to build on the full-scale commercialization
of its technology by enabling the design and fabrication of large,
mass-produced parts and structures. Thus far, it has made carbon
fiber reinforced thermoplastic composite parts for aerospace,
Hemant Bheda is chairman and cofounder of Arevo.
defense, consumer electronics, transportation and consumer
goods medical, and oil and gas.
In July 2018 the company announced the launch of an elec-
tronic version of the 3D printed bicycle – the eBike, reportedly
world’s first battery-assisted bike using a 3D carbon fiber frame.
Arevo says that the eBike can be customized for individual riders,
printed as and when needed at scale, and manufactured any-
where in the world.
Arevo partnered with Oechsler, a German manufacturer of
automotive and medical parts, to use its Drivematic three-speed
automatic gearbox with Arevo’s 3D printed carbon fiber frame
for an electric 3D printed bike. The bike includes Bluetooth capa-
bility and smartphone connectivity making it possible to track
bike data such as battery life, current speed and distance.
‘We’re committed to being at the forefront of manufacturing
innovation, and partnering with Arevo allowed us to explore a
unique use case for our integrated drive system,’ said Michael
Oppermann, a director at Oechsler. ‘With Arevo’s ability to Lyndon Smith, director of fibers at Hexcel.

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 FEATURE Reinforced Plastics d Volume xx, Number xx d xxx 2018

3D printed strong polymer parts from Arevo are reportedly

lighter and stronger than similar products. (Photo courtesy Busi-
FEATURE

ness Wire.)
A high res simulation of the 3D printing deposition path.
(Photo courtesy Business Wire.)

A simulation of the robotic arm performing 3D printing tasks.

(Photo courtesy Business Wire.)

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