Proto Labs cycle carrier prototype
The cycle carrier in use.
Auxtail, a manufacturer of mounted vehicle applications, has harnessed Proto Labs’ 3D printing expertise to make easier the transportation of bicycles via car with a new product.
With traditional methods cycle carriers, Auxtail’s founder, Craig Broadbent, a design engineer, has found drawbacks in the practicalities of the devices, and thus the safety of road users. He set up the business in May 2016 and just over a year later he has multiple rear mounting vehicle platform products on their way to market. They include a platform for pet animals and a multi-purpose cargo carrier, as well as the Easy2Ride – the bicycle carrier tested with the help of Proto Labs.
Easy2Ride is connected to a fitting attached on the vehicle’s bumper beam, rather than a tow bar/ tailgate mount. The strength of the bumper beam allows the carrier to hold more weight, despite its own light nature. In order to protect the cycle frame, the wheels and tyres are used as anchor points, but since it needs to be able to cater for bikes of different sizes, the carrier’s design boasts a tyre grip combining ratchet handle and release facility. The design for the carrier was completed with CAD and Finite Element Analysis (FEA) tools. Once completed, Auxtail decided a diligently managed prototype programme be carried out to ensure the design was feasibly functional. Only then, would the company begin manufacturing the product with injection moulding tooling.
Proto Labs cycle carrier
Easy2Ride.
Auxtail approached Proto Labs. The 3D printing specialist received the CAD models, with material, process requirements and delivery timeframe all defined by Auxtail, via its interactive quotation system online. The original design didn’t see many alterations, but the two companies were able to discuss refinements. Each variation required a revised spec and quote, which Proto Labs would be able to respond to on the same day or by the next morning.
“We were impressed with what Proto Labs could offer us – I knew the company’s capabilities from former connections,” Broadbent said. “Validated by a factory visit, Proto Labs’ expertise and track record for rapid prototyping and 3D printing in the automotive sector made them the obvious partner of choice. Moreover, their interactive quotation system with in-built interactive, design feedback, reassured us that we could keep the project development phase on track.”
The Easy2Ride was then taken to Millbrook Proving Ground for durability testing. In what Auxtail describe as ‘difficult and demanding’ surfaces, the carrier proved effective, and the company preceded to the manufacturing phase with confidence.
Proto Labs cycle carrier
“We knew that in addition to carrying out stimulation tests, we would have to test the prototype ‘in the field’,” Broadbent added. “To make this work successfully and to give us the most accurate outcome, it was important for the Easy2Ride prototype to reflect production level qualities as closely as possible. In the event, Proto Labs produced a product with a 90% match in terms of material qualities. For us this was an excellent outcome to take us forward.
“We have established what I consider to be a very good and mutually beneficial relationship with Proto Labs. There are still some cosmetic developments to work on with Easy2Ride, but I have absolute confidence that Proto Labs will deliver what we need. Future plans include developing a three bike version of the product with other rear fixing-based options under consideration. Although it’s relatively straightforward to design the metal work elements, developing the handle, grip and release components for specific applications will enable us to innovate and deliver unique qualities and solutions for the user.”
