News: Take the Skeleton Challenge with Materialise UK

Visitors to the Materialise UK Ltd stand at TCT Live 2010 show later this month will be able to experience the thrills of extreme winter sport with Bromley Technologies Skeleton Challenge.

The Challenge uses a unique skeleton simulator, combining head mounted 3D technology with a composite sled, manufactured by Materialise, and incorporating sophisticated balance and movement systems. Riders can test their skills on simulations of some of the world's most challenging skeleton bobsleigh tracks, where competing athletes can travel at speeds of up to 90mph, and experience 5Gs in some bends.

Following strict guidelines the simulator sled pan, supported by Yorkshire Forward's Rapid Additive Manufacturing Programme, was built using additive layered manufacturing technology.

As the simulator is used in the public domain, particularly within schools, the pan needed to withstand up to 100Kg weight load. Following technical discussions with Materialise, Bromley chose to opt for the FDM solution, using a sparse build to keep the weight to a minimum whilst maintaining the mechanical strength. The pan was painted to a high gloss standard to emulate the real pan.

Following the success of the pan, Materialise in collaboration with Bromley Technologies; and other companies at the Advanced Manufacturing Park (AMP) in Rotherham, produced an enhanced aerodynamic technology package in record time for two of Team GB's top skeleton bobsleigh athletes ahead of the Vancouver Winter Olympic Games.

As aerodynamics are relatively easy for competitor teams to copy, the ultimate aerodynamic design was finalised after the last race of the World Cup season leaving a very short turn around time to test the proposed package, analyse the results and make the decision to go ahead with the new designs or not.

The pan was designed, manufactured and delivered within 48 hours by Materialise in the UK and Belgium and the University of Sheffield's Advanced Manufacturing
Research Centre with Boeing (AMRC) used their stat-of-the-art five-axis machine to produce moulds in a matter of days.

Philip Hudson, Managing Director of Materialise UK said: "The fact that additive manufacturing technologies like FDM & stereolithography are being used more frequently in these types of applications is proof that the techniques and materials have improved in such a way that they can be used in production environments.

"The use of additive manufacturing processes does not only offer obvious cost and lead-time advantages, but also provides increased design freedom and the possibility to customise products. By producing only what you need, additive manufacturing offer a clear advantage over traditional subtractive technologies."

Taking place annually, TCT successfully draws together everyone involved in the concept, design, manufacturing and specification functions. TCT Live 2010 takes place on October 19 - 20 at the Ricoh Arena, Coventry.

Materialise website
Bromley Technologies

Images: materialise.com