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293D fab+print - May / June
[ AUTOMOTIVE ]
When will 3D printing be available
at Honda 2-Wheels European Design
Center?
3D...
30 3D fab+print - May / June
[ AUTOMOTIVE ]
About the Honda R&D Rome Studio
It was formed in 1996 when a small group of It...
313D fab+print - May / June
[ AUTOMOTIVE ]
About Antonio Arcadu
Antonio Arcadu has been modeling Coordinator at the Concep...
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3D fab+print "Saving on scheduling and production time at Honda R&D " Interview Antonio Arcadu

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The automotive industries are characterized by high budgets and extremely tight implementation
schedules when applied to new designs. The implementation phases involved in bringing
out a new design can nevertheless be long and complicated. In this article, Antonio
Arcadu, Design Modeling Coordinator at Honda R&D, Europe, Italy gives an insight into
how 3D modeling techniques are not only simplifying design procedures at Honda but
also helping to cut costs and increase production efficiency.

Published in: Automotive
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3D fab+print "Saving on scheduling and production time at Honda R&D " Interview Antonio Arcadu

  1. 1. 293D fab+print - May / June [ AUTOMOTIVE ] When will 3D printing be available at Honda 2-Wheels European Design Center? 3D printing has been used in prototyp- ing processes for over fifteen years now. However, relatively recently there has been a massive explosion in the use of such techniques thanks to the increasing dissemination of Fused Deposition Modeling (FDM) printers. In fact, several years ago, the Honda R&D Europe, Italy, acquired an FDM printer to support the company’s mod- elers, not only during the clay-modeling creation phases of design but also during the whole implementation process. This latter process involves the stages from developing the clay model in to the final mock-up model Saving on scheduling and production time at Honda’s R&D The automotive industries are characterized by high budgets and extremely tight implementation schedules when applied to new designs. The implementation phases involved in bringing out a new design can nevertheless be long and complicated. In this article, Antonio Arcadu, Design Modeling Coordinator at Honda R&D, Europe, Italy gives an insight into how 3D modeling techniques are not only simplifying design procedures at Honda but also helping to cut costs and increase production efficiency. The headlight of the Honda cB4 model. A clay model. that will be used on show at interna- tional events. The artistic process, which is car- ried out after the stylistic direction definition phase, and the subsequent completion of the technical package led to the realization of the first aesthetic evaluation model. This can effectively be called a ‘sculpture’- made by the modeler’s expert hands. It is a model of how they interpret and model the shapes in clay. All these individual elements would normally take a very long time to model manually. As a result, they are produced instead in 3D, and are then printed and inserted into the clay model so that the clay model evaluation phase can be carried out with greater definition and detail. At this stage, because of its dimensional value, 3D printing takes on the specific role of validating the total proportions of the motorbike’s volume. Figure 1 shows a headlight according to its final dimensions. In this particular case we have printed more than ten headlights to various diameters before selecting the appropriate size. How does 3D printing support the final mock-up creation phase? We usually rely on specialized external suppliers with SLS or multi-jet printers for the final mock-up phase. This phase is characterized by a need for great pre- cision.Outstanding dimensional control is A sketch drawing of HONDA CB4 Concept presented at EICMA 2015. Designed by Valerio Aiello.
  2. 2. 30 3D fab+print - May / June [ AUTOMOTIVE ] About the Honda R&D Rome Studio It was formed in 1996 when a small group of Italians joined a few HGA members to establish the R&D office in the most important European scooter market. At the beginning the office was just a branch. We were in charge of all activities related to the scooter market and were especially focused on the coloring for the scooters. Across the years, the office’s activity became more and more important for 2W concept creations, especially for European models. A preview of Honda developments in scooters and motorbikes from 1996 to the present date. also required in order not to compromise either the quality of the model or the subsequent stages that involve painting and finishing. Nevertheless, we also use the FDM during intermediate phases, or for ‘non- visible’ components. For example, we have 3D-printed a component in order to replace a piece of fairing that is cur- rently not available since it will be milled out of aluminum later on. Thanks to the 3D-printed component, the painter can still check the spacing between the differ- ent elements, when considering that the couplings must be constant. Once the missing component is created, the 3D-printed element is eventually replaced. So what about time and costs? The automotive industries are usually known for having very high budgets and extremely tight implementation schedules. In our case, we have to take into consid- eration the needs of the European market. Our target is to present the concept model to our customers to international shows such as EICMA, INTERMOT or the Tokyo Motor Show, the most advanced and mature prototypes, which have a very high-quality of design. As a result, we often use 3D printing more than is actually needed in order to offer more solutions for any particular model and also to explore new possibilities that, more often than not, go far beyond the initial style sketches we make. This freedom is also due to the suitability of the FDM technology that allows us to control costs during the research and volume definition phases. That said, in the implementation phase in question, two months of clay modeling were required to produce the model and three-and-a-half months were needed before the mock-up was ready to put on display. Neverthe- less, these are excellent schedules for us, thanks to 3D printing techniques. Finally, 3D printing offers a great variety of service advantages, not least the simplicity and the evolution of the modeling software, and the democratization through the fab lab of the digital fabrication process. The combination of these factors makes proto- type creating activities faster and cheaper.
  3. 3. 313D fab+print - May / June [ AUTOMOTIVE ] About Antonio Arcadu Antonio Arcadu has been modeling Coordinator at the Concept & Design Develop- ment Department at Honda R&D Europe in Italy since October 2008. His role is that of a Design Modeler specialized in two-wheeler motorbikes. His focus is on the concept of clay mock-ups and the mass production of motorbikes. Antonio is a skilled 3D concept Modeler Nurbs/Polygonal Modeler- with experience in digital fabrication. Additionally, he is an IT Development Group Steering Committee Member, and has much experience in team and project management. Further, he has a broad vision of industrialization processes, time schedules, and budget constraints. His special interests are in 3D printing technology, robotics arm, and VR technology He has been the Modeling Project Leader with regard to the following Honda models: - Honda CT ADV Concept bike EICMA 2015 - Honda CB4 Concept bike EICMA 2015 - Honda CBSix50 Concept bike EICMA 2015 - Honda New CBR600 F, MY 2011 and has been involved in team cooperation development for: - the Honda Africa Twin Adventure Sports Concept EICMA 2015 - the Honda New SH125i/150i ABS MY 2013. Finally, he is an inventor: Patent No. US D0649915, United States Application No. 29/386950, and since July 2014 has also been a Freelance Consultant for digital manufacturing projects and start-up support related product design. Advert Subscriptions

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