Gilera Bi4 Nordwest 3d scanning/modelling

[Matte]

Wow, the head covers are fully detailed and well done, congratulations for the final result.

[Duranti]

Thank you Matte, I always appreciate your comments!

Sorry for the long time since the last update, tomorrow I will be finished with the cylinder head, it has been the most complex part by far of this project (it has taken a ton of time model, really difficult work), and it will be detailed to the same level as the cylinder head cover 

At the end of the project I will make high quality renderings of the complete engine, hopefully I will be able to contribute something valuable to the forum. 

[CFASD]

 
what type or software specialise you'd used?
new 3D printers and systems/technology, such as laser sintering prototipes, with micro layers, it's a good idea, but the budget it's high.
there are 3D printing system for lost wax casting.
'AO.

[Duranti]

Hi CFASD,
There are so many interesting technologies available today, of special interest is of course, as you have mentioned; 3D printed lost wax parts. This opens up to massive reductions in leadtime and cost when developing a product, prototypes can quickly be realized in the "final" material, and real world testing can be performed at a fraction of the cost/time that it takes during normal development/production procedures!

The software I use for 3D modelling is primarily Autodesk Fusion, and Inventor (when my friend lets me borrow his, it's too expensive for an enthusiast like me). For 3D scanning I use the proprietary Nextengine software, including Nextengine ProScan capability extension software (which allows higher accuracy and larger objects to be scanned). 

[Duranti]

And now, here is the Bi4 cylinder head, wow, this was a pain in the neck to model (and I have only replicated the external geometry!), I have enormous respect for the engineers and craftsmen who realized this part, I bow to those people!!!

The last two pictures show the scanned casting and 3D model intersecting eachother, there are some deviations, this is not exact science, but it's as accurate as I can get the model relative to the cast part with the equipment I have at my disposal.
Also the modelling itself was very complex, especially with the tangency between the different geometry (which of course needs to be as good as possible for casting a part), but I am happy with the result, and it is much more accurate than what I need it to be for my application. 

Again, the Bi4 parts are absolutely beautiful, it's easy to see that there is alot of passion and knowledge behind these parts, and it's also easy to understand why the owners of these engines have a special relationship with them!

Next up is the crankcase, will be very interesting work! 

[Matte]

Another great creation, full of difficult parts to reply, bravissimo. The finale result, the entire engine, will be spectacular........

[Duranti]

And now for a little sidestep in the project while I'm modelling the crankcase (which takes much more time than anticipated):
I present one of my plans related to the scanning/modelling of the Bi4; to make a 1:3 scale display model! 

I am going to 3D print all the parts of the Bi4 and assemble into a 1:3 scale model and combine them with a pedestal, to place on the shelf in my workroom, all for the fun of it, and for the enjoyment of the beautiful looks and curves of the Bi4!

The pictures show a rough print of the cambelt cover, the final version will likely be "acetone vapoured" for a smooth finish 
My 3D printer is an Ultimaker 2+, and I'll probably be printing the project in Polycarbonate for a longlasting display model.

It will be a fun project to put together, but all the models need to be optimized first before 3D printing to get the best possible fit, and when they are optimized I will be printing day and night to be able to put together this little beauty quickly!

[bigbore]

Go ahead duranti and work hard.
I think all parts will be ok just in time for christmas... can you imagine? An amazing 1:3 scale Bi4 kit ready to assemble for every Bi4 enthusiast!! a must have surely (and you will be our Santa giving us all .STL file.... right?).

[Duranti]

Hi bigbore,
Perhaps Santa will consider putting together a small series of 1:3 scale Bi4 kits for enthusiasts who would like to help Duranti finance the next project (where the Bi4 3D model will be used) 

[Gatto Silvestro53]

Here we go! A custom made 50cc cylinder, currently running in real size.
Trond please, have a look just for fun ... Exhaust, transfer and porting are in the final shape yet.
Maurizio

[Duranti]

Maurizio,
WOW, a perfect example what is possible with ingenuity, dedication, and knowledge of how to make an idea into a real life object, magnificent work!

I have always wanted to do the same thing as you have done, and seeing your project really makes me want to start planning a project of my own!

With 3D printed models it is the perfect opportunity to do bench flow testing directly on the 3D printed model, and the shapes and sizes of the ports can be optimized to a high level before going to the foundry, which is a huge time and cost saving. There are so many possibilities related to 3D printing a cylinder. 

May I ask if you used lost wax casting, sand casting, or gravity die casting, for creating the real size running cylinder? Also, may I ask which material you chose for the cast part?


Wonderful work Maurizio, I am very inspired, thank you for sharing the picture!   

[Gatto Silvestro53]

Unfortunately I'm not the creator of such a beautiful piece. It's a friend of mine, definitely a very talented guy in mechanics and related items as welding, turning, milling, two stroke tuning and so on. He built all the single negative parts useful for the sand casting giving the optimal shape and direction of all the ducts. The result is a near 20 hp at 16.000 rpm on a Dyno test bench. In the picture you can notice the piston-port version, yet been sand casted and soon available after the nikasil deposition. The current standard unit is without inlet port, useful both for rotary disc and reed valve engines. I know it is under tests by the well known Martijn Stehouer special parts supplier in The Nederlands for a close incoming marketing.
I agree with you that 3D printing give you the most realistic idea of the final product and give you the opportunity to evaluate any needed modification and make them in real time, during bench flow tests also. The real size 3D unit needs more than one night of printer job.
The aluminium alloy is the usual for this applications. I don't know the components percentages.

I'm eagerly waiting to see your 1:3 Bi4 finished. Go ahead!

Maurizio

[bigbore]

Hi bigbore,
Perhaps Santa will consider putting together a small series of 1:3 scale Bi4 kits for enthusiasts who would like to help Duranti finance the next project (where the Bi4 3D model will be used) 

Santa and christmas spirit is dead 






































if it will fit in my always thight budget I'll be glad to contribute to your next project, you deserve it 

[Duranti]

Hi bigbore,
I am sorry for disappointing you, but I am sure Santa will not disappoint this Christmas! 

For now there still remains some time before I have modelled all the parts, and I am still missing a bit of small parts to complete the external geometry of the Bi4, I will scan and model these parts as they arrive in the post! 
Also at the end I will have to make sure that all the dimensions for the mounting positions are as close to the original as possible, hopefully my scanning, measuring and modelling are up to the standard!

Thank you bigbore for your support in the form of posts and comments in this thread, I appreciate it! 

[Duranti]

Maurizio,

Your friend is certainly a highly skilled engineer!
Nearly 20 hp from a 50cc engine is GP level performance, and with today's material technology and coatings it is likely to be reliable horsepower as well, also the Nikasil coating will be a valuable addition to keep friction and wear, and heat to a minimum.
Interesting to hear that the inlet port is not included to allow for different inlet configurations, it wil certainly widen the potential customer base, and give more room for adaptation to existing engine configurations. I hope all goes well with the testing at Martijn Stehouer's, and I hope your friend will get great benefits for his efforts!

Yes, 3D printing a large object like a cylinder would indeed take quite some time, and it would need monitoring (for fused deposition modeling) to make sure that the print is without problems. Stereolithography printing would certainly be the best alternative to get the best possible print for Investment casting from a cylinder pattern, it involves more cost, but the results are close to perfect.

Thank you Maurizio for your interest in my project, I will keep you updated! 

Trond