Although some bikes with similar technology have already been tested in the past, this is the first time ever that a fully functional prototype of a Full E-MTB has been created. This includes the right weight, stiffness and flex.
Source: press release
The novelty is that not only is the development technology an absolute world novelty, but also the final product will be something never seen before in THOK's catalogue: a light E-MTB, equipped with the brand new Bosch SX engine and the possibility of choosing between different battery capacities (400 Wh, 500 Wh, 625 Wh, 750 Wh, plus 250 Wh of battery life extender) to better adapt to the biker's needs (we are considering whether to even have everything integrated into the frame) .
A 3D printed prototype but perfectly functional
'Thok Project P4′ (P4 is the pending abbreviation of the shape and final name of the bike) is the embryo of what will presumably become THOK's first 'light e-bike' in 2024.
Development is underway, with tests on the technical trails of Finale Ligure, currently using the very frame exhibited at Eurobike. None of this would be conceivable with traditional polyurethane or PC-ABS models.
Printing on aluminum replicates carbon fiber shapes
The final bicycle will most likely be made from carbon fiber, but making prototypes out of this material would be time consuming and expensive. 3D printing technology therefore uses other materials. In this case, a powder of aluminum and silicon, which is solidified using a laser beam. The structure is honeycomb to reduce weight.
THOK's prototype consists of six 3D printed pieces, which are then welded together. With this technology, anything imagined in carbon can be prototyped in aluminum.
Extremely fast development times
The benefit of rapid prototyping with 3D printing lies in the ability to field test geometries and configurations, making design changes and modifications to experimental models very quickly.
The production of a bicycle normally requires at least two years of work with meetings, market studies, drawings, development, durability and stress tests, discussions with suppliers and, above all, the creation of prototypes. This is particularly true for those who, like THOK, do not use open mold frames but design their own e-bikes from scratch.
Technology, materials and the right partner
For such a delicate passage, THOK looked for a partner, an excellent travel companion. The choice fell on Materialize, a Belgian company with offices in 20 countries around the world. They specialize in 3D printing for the aerospace, automotive and medical industries.
The technology is Selective Laser Melting (SLM): it is an additive manufacturing procedure that uses lasers to melt metal powder.
It is a material that allows you to create unique shapes, solving problems of structural complexity which, for an e-bike, would require numerous CNC machined parts (a 'subtractive' production process, which instead removes layers of material) and disposable moulds.
It is also possible to create larger models with this alloy than with any other material used in metal 3D printing, which is why it is often used in aerospace and auto racing.
