EOS Additive Manufacturing for the Sport Industry

Sporting success through additive manufacturing: EOS Additive Manufacturing allows product innovations to be implemented in the sport industry, thus offering athletes high-performance sports equipment.

Sporting performance not only depends on athletes’ mental and physical constitution. Equipment is a decisive factor in many disciplines too. High-tech materials and specialized equipment tailor-made to athletes’ requirements lead to success.

To remain competitive, the development departments of the sports equipment industry deviate from series products. They come closer to their objective of optimizing the system "athlete and equipment" with new ideas for product improvements.

These ideas are turned into product innovations through the use of production technologies such as additive manufacturing. This results in the production of robust lightweight versions of complex sports equipment, for example, which would not be able to be produced using conventional production technology.

For athletes, this mainly means one thing: a competitive lead in the fight for medals and podium places.

Additive Manufacturing Kappius rear hub 1a

Kappius rear hub with oversized design (Courtesy: Kappius Components & Ben Delaney/BikeRadar)

Additive Manufacturing Kappius rear hub 1b

Inner pawl ring manufactured from an extremely durable “tool steel” using direct metal laser sintering (DMLS™). (Courtesy: Kappius Components & Ben Delaney/BikeRadar)

Additive Manufacturing Kappius rear hub 1c

Toothed drive ring manufactured from “tool steel” using direct metal laser sintering (DMLS™). (Courtesy: Kappius Components & Ben Delaney/BikeRadar)

Additive Manufacturing Kappius rear hub 2a

The 3D CAD model is used to guide the sintering operation in an EOSINT M 270 System (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2b

The screenshot from the system’s PSW software illustrates how parts are laid out on the build platform to maximize the manufacturing run (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2c

A 200-watt laser melts the powdered maraging steel (bottom left and middle), joining one layer to the next (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2d

A 200-watt laser melts the powdered maraging steel (bottom left and middle), joining one layer to the next (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2e

The finished components are covered in excess steel powder which is then removed using compressed air and recycled before final machining and heat-treating steps are performed. (Courtesy: Harbec).