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.

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. 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. 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