A bicycle “grown” from nylon stockings was put on show yesterday to demonstrate a process that some engineers are calling the most important manufacturing advance since the Industrial Revolution.
The two-wheeler was produced by an EADS research team at Filton, near Bristol, where work on Airbus aircraft is carried out.
The process is known as “additive manufacturing” and involves “growing” products by laying microscopic particles of metal or plastic on top of each other in a 3D printer.
To produce the bicycle, layers of nylon were stacked on each other to create a single structure with the wheels, bearings and axle all made in one piece. The process means that a design can be created on a computer and then printed, removing the costly process of building prototypes.
The use of advanced materials also allows manufacturing companies to build components that are much stronger and lighter because they do not have to be joined, welded or lathed.
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Robin Southwell, chief executive of EADS UK, said: “We can now design a component on a computer and, just like printing a sheet of paper, we can print a product using just powder and lasers.”
Additive manufacturing has been around for several years but it has been possible to grow only relatively small products. However, 3D printers are becoming bigger and the process has become more sophisticated.
Some of the world’s largest manufacturing companies are looking at how they can use additive manufacturing to speed up product development and reduce waste. For EADS, the prize is to build aircraft components that are lighter and stronger than is possible using traditional processes.
Mr Southwell believes it is vital that British companies adopt such technology early to stay ahead of international rivals. “Technological leadership is vital for the UK if we are to have a successful export industry and we need support to be able to develop this sort of product,” he said.
EADS has received about £5 million from the Government to help to develop the “Airbike”. The machine is not for sale but will form the basis of future research by EADS into additive manufacturing.
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Iain Gray, chief executive of the Technology Strategy Board, a government agency, said: “The Airbike is an example of technology innovation, which stands a real chance of providing UK businesses with a manufacturing edge for the future while delivering economic growth both here and around the globe.”