Fusion E-Board 3D Hubs
The Fusion E-Board and its 3D printed components.
A British intern at 3D Hubs has designed and manufactured an electric skateboard using HP’s Multi Jet Fusion technology and Autodesk software.
Jack Davies, a product design student at Nottingham Trent University, was motivated to develop the skateboard as a faster mode of transport to get to the 3D Hubs office in Amsterdam, the Netherlands. He was able to create the Fusion E-Board in less than a week, and at a total cost of €550. Typically, skateboards that boast similar specifications are commercially available at prices starting at €1,500.
The main components of his new mode of transport, the longboard, trucks, deck, and wheels, were parts bought off the shelf and acted as a starting point for the design. Autodesk’s Fusion 360 software was the platform used to model components inside of the main assembly, and put them through simulations to ensure their strength and endurance. He also optimised the design of parts like the motor mounts, reducing the size, cost and material needed. The motor mounts are among the most important mechanisms in an electric skateboard since they hold the motor in place. Such was their importance, and the fact they would dictate the size and location of the board’s enclosures, Jack decided to tackle their design first, along with the gearing set-up and trucks.
“I calculated the desired top speed and torque requirements which then enabled me to select the motors and battery for the board,” Jack explains. “The gearing ratio was also calculated and the pulley sizes were selected, along with the drive belt length. This enabled me to work out the correct size of the motor mounts which ensured a well-tensioned belt. The next stage was to design the batters and speed controlled enclosures.”
Fusion E-Board 3D Hubs
The bend in the Fusion E-Board's deck allows for greater comfort.
The deck selected by Jack, although able to ensure a more comfortable ride for the user, would have design implications for the enclosures. It was predominately made from bamboo, which meant a significant bend in the middle of the board, able to absorb bumps in the road. But it also meant a split enclosure was needed to house the battery and electronics – a full-length enclosure wouldn’t be able to flex with the board and thus would make contact with the ground when in use. At this point, the services of 3D Hubs were required, and Jack made use of the HP MJF 4200 3D printer and a desktop FDM machine too.
HP’s printer was used to create geometrically complex parts, usually made in aluminium, in PA 12 nylon. The protective ribs, which can be seen on the underside of the Fusion E-Board, were one example of the complex parts printed on the HP platform. They needed to flex slightly as the board did, and offer a strong mounting point. The nylon material was also used for the drivetrain and motor mounts, because of the heat resistance and ability to withstand stress it offers. Meanwhile, the larger parts of the build, including the battery cover and pulley system, were printed with the desktop platform. The pulley was printed in ABS, making it a cheap part to replace if it succumbs to wear and tear.
Fusion E-Board 3d Hubs correct caption
The underside of the Fusion E-Board which features protective ribs manufactured with HP's Multi Jet Fusion technology.
3D Hubs has been keen to highlight the innovation of one of its latest interns, and in similar vein, Jack has decided to make his files public to encourage others to solve their problems with modern technologies. Within a week, he was able to build the Fusion E-Board. It weighs 15lbs, has a top speed of 56kmph, a range of around ten miles, and a charge time of four hours. The standard parts cost €350, while the 3D printed components cost €250, meaning the total expenditure was about €1,000 less than buying a similar product currently available.
With a low budget, the cost savings were most welcome, as was the accessibility to a host of 3D printing technology at 3D Hubs.
“Ensuring that the more expensive printed parts would be compatible and function correctly on the first try was the most critical part of the project,” Jack commented. “I had tight budget constraints which meant it wasn’t possible to re-order any parts if there were any mechanical conflicts with the design. A big part of getting it right the first in the industrial machine was to prototype with low-cost FDM parts first, for fit testing.”
Fusion E-Board 3D hubs
Jack Davies rides his Fusion E-Board.
