The first high-performance full electric motorcycles “Ego” was born in Energica Motor Company S.p.A. in Modena, Italy.
Ego was rigorously developed using F1 technologies and the Windform family of high performance composite materials. Energica was created and engineered through the CRP Group, whose decades-long activity in the field of high precision CNC machining and professional 3D printing, along with Windform composite materials for Additive Manufacturing, allowed the creation of innovative and avant-garde solutions that have made Energica a unique model throughout the world.
The use of Laser Sintering technology and Windform composite materials enabled Energica to be on the market quickly, accelerating the prototyping and product development phase.
The CRP Group was fundamental for the industrial development of Energica since the very first prototypes, which contain parts made with Selective Laser Sintering technology and Windform carbon or glass fiber filled composite materials. The materials were engineered by the RD department of CRP Technology, the CRP Group’s company that has been dealing with professional 3D printing for over 20 years.
Energica has also benefited from the experience gained by the CRP Group in over 45 years of activity as a supplier of innovative and cutting-edge technological solutions alongside the major F1, Moto GP, Rally Raid and ALMS teams.
CRP Group recently performed a case study regarding the development of Energica Ego’s motor housing, which will be used by teams that will race the FIM Enel MotoE World Cup.
The object of the case study was the creation of the Energica Ego motorcycle motor housing.
The motor housing is an important component of electric motorcycles, with highly complex features. Energica engineers and CRP Group staff worked together to redesign the component, in order to accommodate the rotor, stator and the speed reducer.
The propulsion unit to be supported is so flexible and compact, that the Energica motor housing can be adapted to any vehicle.
The Energica Ego reducer is composed by straight-cut gear train that adds strength while providing simplicity of design and a pleasing sound.
The structure holds the shaft and pinion and final drive to the wheel with a standard, tried-and-true motorcycle chain.
For the redesign of the motor housing, Energica and CRP teams had to consider different requirements, namely:
– Lightness (since the electric motor was heavy, the housing had to be light)
– High resistance (because the motor generates a high torque)
– Correct sizing of the gears and appropriate choice of materials/ heat treatments.
The housing was created in three steps: creation of the 3D printed functional prototype, creation of the prototype CNC aluminum billet and rapid casting and realizing models for pre-series.
For more information on the case study, click here.