The future of manufacturing…on two wheels

• EADS produces world’s first bike using revolutionary ALM technology - ‘grown’ from high-strength nylon powder
• Called the ‘Airbike’ because Airbus was the first EADS company to use the technology
• New technology will transform manufacturing around the globe

Bristol, 7th March 2011 – EADS, the European aerospace and defence group,
has unveiled the world’s first bike that uses a revolutionary new manufacturing
process which demonstrates the potential to transform manufacturing around
the globe.

Known as the ‘Airbike’, it is a bike with a difference. Made of nylon but strong
enough to replace steel or aluminium, it requires no conventional maintenance
or assembly. It is ‘grown’ from powder, allowing complete sections to be built
as one piece; the wheels, bearings and axle being incorporated within the
‘growing’ process and built at the same time. The Airbike can be built to rider
specification so requires no adjustment.

The revolutionary manufacturing process is known as Additive Layer
Manufacturing (or ALM) and it allows single products to be grown from a fine
powder of metal (such as titanium, stainless steel or aluminium), nylon or
carbon-reinforced plastics from a centre located next to Airbus’ site at Filton.
Similar in concept to 3D printing, the bike design is perfected using computeraided design and then constructed by using a powerful laser-sintering process
which adds successive, thin layers of the chosen structural material until a solid,
fully-formed bike emerges.

Robin Southwell, Chief Executive of EADS UK, commented: “The Airbike is a
fantastic example of British innovation at its very best. The team at EADS in
Bristol includes world-class engineers who continue to push boundaries by
working at the forefront of technology. I believe that ALM technology represents
a paradigm shift.

While the Airbike is only a technology demonstrator at this stage, EADS has
developed the technology to the extent that it can manipulate metals, nylon, and
carbon-reinforced plastics at a molecular level which allows it to be applied to
high-stress, safety critical aviation uses. Compared to a traditional, machined
part, those produced by ALM are up to 65% lighter but still as strong. The
technology is likely to be employed in due course in industrial applications such
as aerospace, the motor industry and engineering. Studies show that for every
1kg reduction in weight, airlines can save around $3500 worth of fuel over the
lifespan of the aircraft, with corresponding reductions in carbon-dioxide
emissions.

Minister for Business and Enterprise, Mark Prisk, said: "I am proud to see the
UK - through EADS and others - leading the world in the development of
innovative products. Additive Layer Manufacturing, or ‘3-D printing’, is a truly
exciting, green, new technology, which not only enables the creation of products
beyond the capability of traditional manufacturing processes, but also offers the
potential to help the manufacturing sector slash its waste and carbon emissions.
This is exactly the sort of advanced technology that we want to see companies
investing in, here in the UK."

ALM also offers a glimpse of wider potential benefits. The process itself uses
about one-tenth of the material required in traditional manufacturing and
reduces waste. On a global scale, ALM offers potential for products to be
produced quickly and cheaply on ‘printers’ located in offices, shops and houses.
It would allow replacement components to be produced in remote regions,
improving logistics on humanitarian relief and military operations.

Andy Hawkins is the lead engineer for ALM at EADS. “The possibilities with
ALM are huge – it’s a game-changing technology. The beauty is that complex
designs do not cost any extra to produce. The laser can draw any shape you
like and many unique design features have been incorporated into the Airbike
such as the auxetic structure to provide saddle cushioning or the integrated
bearings encased within the hubs.”

Further ahead, by removing production lines and the need for factories, the
costs of ‘manufacturing’ will be significantly reduced and, through this, ALM has
the potential to reverse trends of urbanization that have historically
accompanied industrialization.

Iain Gray, Chief Executive of the Technology Strategy Board, said: “It is hugely
exciting to see examples of British engineers showcasing their work so
effectively. The ‘Airbike’ is an example of technology innovation which stands a
real chance of providing UK businesses with a manufacturing edge for the
future while delivering economic growth both here and around the globe.”

Whilst there are currently limitations in terms of the maximum component size
achievable and the costs involved, the technology is developing fast. There is
growing recognition of the potential ramifications of ALM and the barriers to
delivering this technology on a global scale are falling rapidly

EADS Press Release