This document discusses using digital manufacturing techniques to create customized motorcycle seats. It proposes using 3D scanning and pressure mapping of riders to collect empirical and subjective data on their comfort needs. This data would then be used in computer modeling to design seats with graded stiffness zones tailored to individual riders. The customized designs could be fabricated using laser sintering to produce seats offering improved ergonomics and comfort.

1. RM: Innovation
for, through, and of Extremes
By Jason Jones & David I. Wimpenny
De Montfort University
Innov_ex 09 9 May 2009

7. Source:http://en.wikipedia.org/wiki/Gulf_war

8. Source:www.byu.edu

10. Source:http://en.wikipedia.org/wiki/Sugarloaf_Mountain,_Brazil

12. RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes
& of

13. RM: Innovation
J. Jones Innovex 09 9 May 2009
through,
Extremes

14. Source:http://www.notjustrocks.com/uploads/TXColmesneil8-2L.jpg

15. Source:http://www.notjustrocks.com/uploads/120306-6L.jpg

16. Source:http://www.notjustrocks.com/uploads/AZFlorence-1L.jpg

17. LS
Lighting + Sand =
Fulgurite
(fulgurite.com)
Source:http://www.notjustrocks.com/uploads/AZFlorence-1L.jpg

18. LS
Lighting + Sand =
+ Metal Powder
+ Plastic Powder
Laser
Laser Sintering (LS)
Source:http://www.notjustrocks.com/uploads/AZFlorence-1L.jpg

19. Laser Sintering (LS or SLS)
3D Systems EOS

21. Source:www.byu.eduSource:http://en.wikipedia.org/wiki/Amber

22. Source:www.byu.eduSource:http://en.wikipedia.org/wiki/Amber
SLA
Stereo Lithography
Apparatus(SLA)
Sap Left for Ages

23. Stereolithography (SLA)
3D Systems

24. Terminology
LSSLA
FDM
3DP
SLMJetting
USC
LENS
SLS

25. RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes
& of

26. RM: Innovation
J. Jones Innovex 09 9 May 2009
for,
Extremes
& of

27. Source:www.carpentertrade.com/ordering.html;en.wikipedia.org/wiki/Grip_(gymnastics)

29. Source:ducati.com

33. • Pressure a helmet exerts on the head
Correct helmet Small helmet Customized
helmet

34. What is Custom-Fit?
is:
• A Paradigm where
• Digital Manufacturing is
• Driven by Customer Data in order to
• Produce Customised Products for their Body

35. What are you going to change?
Customised liner
Padding
EPS

36. How to do it?
1. Start with a 3D helmet model in the
computer
2. Scan the head
3. Morph the helmet design to fit the head
4. Make the helmet
Source:Custom-fit.org

37. 3D scanning

38. Automated design

39. 30/01/2015
Result

40. 30/01/2015
Growing Wish List

41. (Results: failure. HIC = 2460; peak = 280G)

42. The Next Generation

43. The customer is always right.
Source:Ducati.com/LoughboroughUniversity

44. Customer feedback
92% of the motorcyclists
surveyed feel discomfort from the seat
when travelling long distances
Source:Ducati.com/LoughboroughUniversity

45. • Results from on line survey: motorcycle seats
Do motorcyclists want customised seats?
Yes,
81.10%
No,
18.90%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
Customised Seats according to Body
Geometry
Customer feedback
Source:Ducati.com/LoughboroughUniversity

46. • Results from on line survey: motorcycle seats
Customer feedback
Yes, 78.9%
No, 21.1%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
Willingness to Pay for Customised Seats
up to
€250, 66%
<€500,
31.30% >€500,
2.70%
0%
10%
20%
30%
40%
50%
60%
70%
Willingness to Pay
Willingness to Pay and Wait
Source:Ducati.com/LoughboroughUniversity

47. What part(s) to change?
Stability
Pad (inside)
Comfort
Aesthetics
Cover (sky)
Bottom
Cover (sky)

48. How to meet customer need?
• What bike part(s) to change?
– The Seat
• How to drive the changes?
• What changes to make?
Source:Ducati.com

49. How to drive the changes?
• Unsuccessful attempts:
Scanning Measuring
Source:Human-solutions.com(farleft)

50. • Success: Empirical data from Pressure Map
How to drive the changes?

51. How to drive the changes?
• What about subjective data (your feelings)?
Source:IBV
Emperical Data
(mm Hg)
Subjective Data
(Feelings)+
Hybrid Data
(Comfort Map)=

52. How to drive the changes?

53. How to drive the changes?

54. How to drive the changes?

55. How to drive the changes?

56. How to drive the changes?
Zone 3
Zone 2
Zone 1

57. How to meet customer need?
• What part(s) to change?
– The Seat
• How to drive the changes?
– Empirical + Subjective Data
• What changes to make?
Source:Ducati.com

58. What changes to make?
• Laboratory Stiffness testing:
– Establish the dynamic performance of the
standard seat material (benchmark)
– Explore the performance of alternative materials

59. What changes to make?
• Create a “pseudo pocket sprung” seat
– Using CAD & Computer Analysis (FEA) to
– Hollow out the inside of the seat
– Use the force vs. displacement curves from the
laboratory stiffness tests to design individual
“spring” like structures.

60. What changes to make?
• Using CAD & Computer Analysis (FEA):
– Make an array of the “spring” like structures
– Insert them into the seat according to…

61. What changes to make?
• …the customer defined Comfort Zones with
the customer specified stiffness

62. What changes to make?
• Customised Seat making application

63. • Customised Seat making application

64. How to meet customer need?
• What bike part(s) to change?
– The Seat
• How to drive the changes?
– Empirical + Subjective Data
• What changes to make?
– Graded stiffness
Source:Ducati.com

65. The virtual result

66. The virtual result

67. The virtual result

68. Digital fabrication
• Validated design using: Laser Sintering
3D Systems EOS

69. The result

70. Ducati seat
Top side Under side

71. Learning Outcomes
• Is the right material available?
• How we will collect the data (3D scanner)?
• What regulations might be barriers (CE, UL)?
• Will the market pay for the added value?

72. RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes
& of