Simone Di Piazza DUCATI MOTOR HOLDING

1. Ducati lightweight design
Simone Di Piazza
Head of Innovation and R&D Services

4. Ducati’s remarkable history began in 1926 with the launch of Radio Brevetti.
Ninety-six years of history and beyond.

6. Generating real character
through design, detail
and ultimate quality.

7. Born to seduce,
in true red style.

8. The ultimate in
weightlessdesign
throughcutting-edge
innovation.

9. Conceived, created
and crafted to the
finest degree.

10. True performance harnessed
to ensure safety, comfort
and riding pleasure.

11. Beyond the style, motorcycles designed
to deliver superior performance.

16. Assembly Plant CKD AssemblyPlant
Main ProductionPlant
DNA
Ducati North America
Sunnyvale - California
DWE
Ducati West Europe
Paris - France
DJ
Ducati Japan
Tokyo -Japan
DNE
Ducati North Europe
Silverstone - GreatBritain
DDE
Ducati Deutschland
Neuburg - Germany
DAPAC
Ducati Asia Pacific
Rayong -Thailand
DDB
Ducati do Brazil
Sao Paolo - Brazil
DIND
Ducati India
New Delhi - India
DC
Ducati China
Shanghai - China
DANZ
Ducati Australia
Sydney- Australia
DCH
Ducati Swiss
Feusisberg - Switzerland
Borgo Panigale, Bologna Italy Site
surface sqm
Built surface sqm
Amphur Pluakdaeng Rayong Thailand
Site surface sqm
Built surface sqm
Manaus (Dafra Service Provider) Brazil
Ducati Motor Holding
Ducati at a glance

17. Ducati retail sales
Worldwide
59,447
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021

18. Contemporary and iconic as only a Monster can be,
with its unmistakable personality and compact,
essential design.

19. History of an icon - M900 (1993)
In 1992 Ducati unveiled a new prototype that was to become an icon. Ducati's creation
awed the crowds and the world's media of that year's "Cologne International
Motorcycle show".
Monster designer Miguel Galluzzi said of the philosophy behind his creation: "All you
need is: a saddle, tank, engine, two wheels, and handlebars."
Steel trellis frame

20. History of an icon - M696 (2008)
The Monster 696: the beginning of a new era. Enhancing the “less-is-more”
philosophy that has made the Monster a global legend, the Monster 696 continues to
redefine expectations.
Every finely engineered element of the chassis and engine is on display allowing the
true beauty of the 696 to be showcased for all to see. Naked ambition has never been
so graphically described.
Al permanent mould casting rear frame

21. History of an icon - M1200 (2014)
More than two decades on from the Monster’s first unveiling, Ducati now introduce
the iconic model’s latest generation with the 2014 Monster 1200 and 1200 S powered
by the formidable, Superbike-derived 1198 Testastretta 11° DS engine.
The model’s signature Trellis frame still features predominantly in the overall styling,
while its attachment points move directly to the new engine’s cylinder heads, a
method pioneered on the innovative Panigale Superbike.
Steel trellis rear frame

22. History of an icon - New Monster (2021)
The new Monster embodies the true essence of Ducati in its most compact, essential
yet light appearance possible. The name immediately reveals its inner nature. Monster.
Nothing else.
The original recipe dates back to 1993: a sporty engine yet suitable for road use
combined with a Superbike-derived frame, namely everything riders need to taste in
the name of everyday riding enjoyment.
GFRP rear frame

23. New Monster rear frame
The sleek tail, attached directly
to the engine, has a visible rear
frame with both a structural and
aesthetic function.
A single element made of GFRP
(Glass Fiber Reinforced Polymer)
acts as a load-bearing tail and as
a support for all the electrical
and electronic parts.

24. Material choice was guided by mass and costs evaluation:
New Monster rear frame - Material
Technology Mass Cost
Steel trellis frame ref ref
Al die casting (3.5mm) -20% 25%
Al die casting (4.5mm) -3% 40%
Technopolymer -25% 0%

25. Ixef ® PARA UV stabilized, 50%GF was chosen for its characteristics:
› Very High Strength and Stiffness
› High Flow for Thin-Walled Parts
› Excellent Surface Finish
› Low Warpage
› Good Dimensional Stability
› Slow Water Absorption Rate
› Very Low Creep
› Good Chemical Resistance
New Monster rear frame - Material

26. A dedicated embossing (PP1195) was developed to give the part an aesthetic value:
New Monster rear frame - Material

27. Traditionally the part is designed in order to:
› support rider and passenger inertial loads
› meet homologation requirements (passenger’s handles and strap)
New Monster rear frame – Design and development

28. But the part is also subject to the heat transmitted by radiation from the exhaust pipe and
by conduction from the engine to which it is connected.
For GFRP the design process was changed with respect to that used for metallic materials.
New Monster rear frame – Design and development

29. An experimental test campaign was carried out to evaluate the temperature levels reached
by the part during several standard maneuvers (warm up, stop & go, heat stroke):
› First on PROTO bike
› Then on first samples (AVANSERIES)
3 main areas with different temperature levels have been identified.
New Monster rear frame – Design and development

30. The supplier conducted process simulations to verify filling of the mould, parting lines and
fibre orientation:
New Monster rear frame – Design and development

31. The part was designed taking into account the following aspects in the 3 main areas:
› Temperature
› Humidity
› Fibre orientation
Penalty coefficients were defined starting from the data provided by the material supplier.
New Monster rear frame – Design and development

32. Detailed FEM analysis were conducted to verify stress levels on the 2 load cases:
New Monster rear frame – Design and development
High temperature areas Low temperature areas
Static cold load case

33. The two-figures mould was designed with sequential injection to guarantee complete
filling and desired fibre orientation:
New Monster rear frame – Design and development

34. First off tool samples showed repetitive defects (“porosities”) during RX analysis:
New Monster rear frame – Process setup

35. To avoid the defects both geometry and process parameters have been modified:
Gate
dimensions
Wall
thickness
reference
Holding time +10s
Holding time +15s
New Monster rear frame – Process setup

36. The correct setup of the process was verified through a dedicated control plan :
New Monster rear frame – Process setup

37. › Lightweight design of a highly structural part was achieved through metal replacement
› Design methodology was adapted to take into account GFRP material characteristics,
mechanical, thermal and chemical
› It was necessary to modify also development process accordingly; temperatures mapping
› Process simulation was coupled with structural analysis to correctly predict the behavior of
the part: parting lines, fibre orientation
› NDI testing was necessary to detect defects on first off tool samples
› Process simulation guided the modifications needed to geometry and process parameters in
order to avoid defects
› An appropriate definition of the control plan ensured the quality of the components
Final remarks

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Simone Di Piazza
Head of Innovation and R&D Services
DUCATI MOTOR HOLDING
Via Cavalieri Ducati, 3
40132 Bologna, Italy
simone.dipiazza@ducati.com
Mob. +39 366 6365959