Aerospace corporation Airbus's Light Rider concept motorbike looks a bit like something HR Giger would draw (although his, of course, would be much cooler). In reality, the 3D-printed frame was inspired by skeletal structures that enable its bare-metal frame to weigh just 13 pounds but support a 220 pound rider. From the BBC News:
To design the bike's frame and swingarm rear section, (Airbus's) APWorks team collaborated with Altair Engineering, a US-based consulting company whose structural-design software works through the principle of "morphogenesis" — which in biology refers to process of environmental forces defining a natural organism's form and structure. Morphorgenetic software is written to create forms that achieve maximum strength with minimal mass, and Altair's system has contributed to the designs of such boundary-pushing machines as the Boeing 787 Dreamliner, the Volvo Ocean 70 racing yacht, and the jet-powered Bloodhound SSC, which next year will attempt to break the land speed record…
The 3D-printing process employed to produce the Light Rider's frame is a marvel unto itself. The system uses a laser to melt powdered aluminium alloy in thousands of layers, each only 60 microns thick — about the width of a human hair. Airbus Group Innovations, the company’s research arm, developed the frame's aircraft-grade alloy, called Scalmalloy, which it claims matches the specific strength of titanium. The fabrication process — and the strength of the material — allows the morphogenetic software to specify finer and thinner structures than traditional tooling or moulding methods of manufacturing can produce. In fact, notes Gruenewald, the Light Rider’s frame even features hollow branches that hide cables and other components.
