VŠB-TU Ostrava vytiskla koloběžku s unikátním kovovým rámem

Technologie 3D tisku zaznamenala pozoruhodný milník – první koloběžka s unikátním rámem z 3D tiskárny byla vytištěna na Vysoké škole báňské – Technické univerzitě Ostrava. Prototyp s bionickou konstrukcí z korozivzdorné oceli je plně funkční a ve srovnání s klasickou koloběžkou zcela obstojí. Unikátní koloběžka vznikla na 3D tiskárně Renishaw AM400, která jemný kovový prášek zcela roztaví a následně ho klade do prostorového modelu po vrstvách.

„Náš prototyp se odlišuje hmotností, rám o váze 3,2 kilogramu je zhruba o čtvrtinu lehčí, než kdyby byl vyrobený tradiční metodou. Vedle úspory materiálu, které jsme docílili tím, že součástky jsou odlehčené a duté, jsme položili největší důraz na atraktivní design koloběžky a její výrazný sportovní vzhled“, uvádí Marek Pagáč, který tým strojních inženýrů z VŠB-TU Ostrava řídí pod hlavičkou centra 3D tisku Protolab.

Kovový rám je dutý, v tom spočívají výhody aditivní výroby. Vizulizace: SolidWorks Visualize

Při navrhování konstrukce byly uplatněny principy bioniky, tedy oboru, který využívá poznatky ze studia živých organismů a jejich struktur pro vývoj nových technologií. Design a výroba rámu se nakonec ukázaly být největší výzvou. „Chtěli jsme zachovat tuhost rámu a současně snížit hmotnost. Komplikované to bylo zejména u jeho přední části, která je dutá a náročnější pro výrobu. Nakonec jsme vše vyřešili tím, že jsme rám rozdělili a vytiskli čtyři díly, které bylo potřeba znovu svařit,“ vysvětlují Lukáš Jančar a Jakub Měsíček, konstruktéři bionické konstrukce a výpočtáři topologické optimalizace.

Koloběžka je moderní trend

Projekt vzešel ze spolupráce s globální společností Renishaw, která VŠB-TU Ostrava před dvěma roky zapůjčila stroj Renishaw AM 400 pro 3D tisk z kovového prášku. „Těší nás, že to byla právě naše 3D tiskárna, na níž byla vytištěna první koloběžka na světě. Obdobně před dvěma roky z našich technologií přišlo na svět první kolo z titanové slitiny,“ připomíná primáty strojírenské firmy proslulé svým inovativním přístupem Josef Sláma, generální ředitel Renishaw pro Českou republiku.

K nápadu vytisknout koloběžku dospěl tým vylučovací metodou. „Z průzkumu trhu jsme zjistili, že se automobilový koncern BMW zabýval 3D tiskem konstrukce elektromotocyklu a letecký koncern Airbus poukázal na výhody 3D tisku před dvěma roky bionickou konstrukcí motocyklu z lehké kovové slitiny. Z titanové slitiny 3D tiskem postavila společnost Renishaw rám jízdního kola. Chtěli jsme jít cestou něčeho, co dosud nebylo realizováno. Navíc koloběžky v současné době zažívají obrození, spousta lidí na nich jezdí, což nám také připadalo přitažlivé. Doposud jsme nenarazili na informaci, že by někde ve světě existovalo něco podobného,“ říká Petr Štefek, business development manager Protolabu a mentor týmu.

Nikdo z týmu konstruktérů sám na koloběžce nejezdí, a proto realizační tým vycházel z modelu českého výrobce Kostka, který se jim stal referenční předlohou pro vlastní návrh. „Potřebovali jsme změřit základní geometrické parametry, abychom je mohli přenést do vlastní konstrukce,“ dodává Jakub Měsíček. Z této úvahy mělo vzejít rozhodnutí, zda konvenčně vyráběnou koloběžku lze vůbec replikovat s pomocí aditivní výroby.

Koloběžka z pohledu kamery:

Jak to bude dál? Koloběžka druhé generace

Během testování v areálu univerzity získal vývojářský tým užitečné podněty pro vývoj koloběžky druhé generace, kterou v současné době konstruují. Vývoj inovované koloběžky právě probíhá a v červnu se očekává zahájení výroby 3D tiskem, v srpnu by měla být koloběžka provozuschopná. Nový model bude podle předpokladů představen v říjnu tohoto roku na Mezinárodním strojírenském veletrhu v Brně.

Tvůrci odhadují, že náklady na vývoj a výrobu unikátní koloběžky se pohybují v řádech několika stovek tisíc korun, protože větší část rozpočtu projektu pokrývají režie na rozvoj zkušeností s topologickou optimalizací a navrhováním bionické konstrukce. Pokud by měl být projekt komercializován, pak se s počtem výroby koloběžek cena pravděpodobně sníží. Výhodou je tzv. kustomizace, kde lze navrhnout koloběžku skutečně na míru zákazníkovi. Rám lze optimálně propočítat na váhu člověka a konstrukci podřídit ergonomii.

Projekt by se neobešel bez spolufinancování, které podpořil rozpočet Technologické agentury ČR v rámci projektu PRE SEED fond VŠB-Technické univerzity Ostrava, kde je řešitelem Centrum podpory inovací. Budoucnost projektu záleží na výsledku druhé generace koloběžky a dalším vývoji technologií, například na tom, jak se bude zvětšovat stavební komora 3D tiskáren a s ní i objem produktů, které půjde tisknout najednou. S ohledem na velikost předního rámu by bylo ku prospěchu tisk z jednoho dílu, čímž by se odstranil technologický proces svařováním.

3D tisk a aditivní výroba jako samostatný předmět ve výuce

Aditivní výroba coby proces používaný pro tvorbu trojrozměrných objektů z digitálních dat, jak se někdy 3D tisk pro průmyslové účely nazývá, je velmi mladý obor. „Pohybujeme se v něm teprve třetím rokem, ale vidíme v něm velkou perspektivu,“ říká vedoucí centra 3D tisku Marek Pagáč. I to je důvodem, proč se 3D tisk jakožto předmět Aditivní technologie začal v rekordně krátké době vyučovat na Fakultě strojní jako volitelný předmět. V současné době se s 3D tiskem setkají studenti navazujícího magisterského studia ve studijním programu Strojní inženýrství a o studium projevuje zájem čím dál více studentů.

Cílem je přenést předmět do bakalářského studia studijního programu Strojírenství, kde by byla osnova předmětu zaměřena především na možnosti technologií 3D tisku a studentům by byl předmět prezentován populárně-vzdělávací činností. Odborně-vzdělávací charakter s vědecko-výzkumným potenciálem by byl prezentován následně v navazujícím magisterském nebo doktorském studijním programu Strojní inženýrství, obor Strojírenské technologie. Odezvu má centrum 3D tisku i od studentů ze středních škol, kteří již zjišťují, co se na VŠB-TU Ostrava naučí a jaké má škola vybavení.

Moderní design vznikl po vzoru rostlin. Říká se mu bionická konstrukce. Vizualizace: SolidWorks Visualize

V současné době má Fakulta strojní dvě 3D tiskárny pro tisk z práškových kovů a jednu pro 3D tisk z polymerních práškových materiálů. V následujících třech měsících se centrum 3D tisku pod hlavičkou Protolab rozroste o 3D tiskárnu pro tisk z práškových kovů, jednu 3D tiskárnu pro tisk z práškových polymerů a jednu 3D tiskárnu pro tisk metodou FDM s vyztuženými vlákny z kompozitních materiálů.

Kromě toho připravuje zavedení meziuniverzitního oboru Průmyslový design společně s Univerzitou Palackého v Olomouci, kde bude pro účely výuky zakoupena 3D tiskárna pro tisk z práškových kompozitních materiálů. Protolab se tak stane největším centrem 3D tisku v Česku a na Slovensku co se týče počtu průmyslových 3D tiskáren zaměřených na tisk z práškových materiálů. Kromě toho centrum pro účely spolupráce s průmyslem a výuku studentů používá profesionální software pro konstruování, topologickou optimalizaci, simulaci a predikci 3D tisku.

Jak první „tištěná“ koloběžka přišla na svět

Pro vytvoření trojrozměrného dílu se zpravidla využívá technologie nanášení či tuhnutí tenkých vrstev materiálu. Díky tomu lze vytvářit složité tvary, které nelze vyrobit tradičními technologiemi, jako jsou odlévání, kování a třískové obrábění. Aditivní výroba přináší nové konstrukční možnosti. Umožňuje vyrábět složité dílce, které by jinak musely být vyrobeny z více kusů. Snižuje nároky na množství materiálu a také snižuje náklady na nástroje.

Koloběžka z Ostravy ovšem není čistě produktem 3D tisku, ale vznikla také s přispěním tradičních metod. „Svařování jednotlivých dílů rámu v ochranné atmosféře argonu bylo jednou z nich, vedle toho jsme lepili prvky z uhlíkového kompozitu a obráběli funkční plochy. Ty bylo potřeba kromě toho ještě omílat, abychom získali jejich hladký povrch,“ upřesňuje Lukáš Jančar z Technické univerzity Ostrava.

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