Nera E-Motorcycle BigRep NOWlab 3D-Printed

Just 15 Parts? 3D Printed? E-Bike? Fully Functional? Yes, that’s BigRep’ Nera

12 weeks of conception & just 3 weeks printing


Just what the guys need!

All black, electric and completely 3D-printed. BigRep’s Nera Motorcycle is here, and ready to change the game.

The electronic components of this brand new, futuristic-looking motorbike are the only elements that weren’t created on large-scale 3D printers.

Flexible parametric bumper replaces the traditional suspension as a shock absorber, and those custom tires are as cool as they are intriguing.

Only 12 weeks after its conception and just 3 weeks printing at the BigRep headquarters, NERA E-Motorcycle took its maiden voyage in Berlin.

A very simple idea : create a functional prototype that would revolutionize e-mobility.

The execution, however, was incredibly complex. NERA was designed from the ground up and every aspect of traditional motorcycle engineering and production had to be rethought.

As you can witness, the result is a functional prototype that is completely customizable, made faster and cheaper than ever before possible.

Daniel BüningCo-Founder and Managing Director of the lab explains,

This bike and our other prototypes push the limits of engineering creativity and will reshape am technology as we know it.’

Nera E-Motorcycle BigRep NOWlab 3D-Printed
3D printed from head to tail

In building NERA, the engineers didn’t simply adapt existing motorcycle designs.

Instead they envisioned a bike for large-format FFF(fused filament fabrication) technology which feeds a continuous filament of thermoplastic material through a moving, heated printer extruder head, setting a benchmark for truly creative design.

Now that's what I'll call as breaking the limits of traditional mechanical engineering.

NERA bike was designed by two NOWlab experts, Product Designer Mattia Cristofori and Maximilian Sedlak, an Applications Specialist and Parametric Designer.

More than just an exercise in what can be achieved with 3D printing – and specifically FFF printing with BigRep technology – NERA shows that the low cost and fast results of additive manufacturing allows designers to immediately test prototypes and rapidly produce iterations of experimental engineering.

Nera E-Motorcycle BigRep NOWlab 3D-Printed

Billed as a "world's first" by the company, all parts of the Nera electric motorbike (that’s 15 components in total) – excluding the electrical components – have been 3D-printed. These include the tyres, rims, frame, fork (which connects the front wheel and axle to the frame) and seat.

The electric engine of the bike is encased in a 3D printed shell, and the motor is integrated into the back wheel of the bike.

From the headlights to the taillight, the NERA measures 190 cm, and stands at 90 cm high.

3D printed parts of the NERA motorcycle were made with BigRep’s large-scale FDM 3D printers using a range of materials. For your curosity I have already listed them below.

Materials Used

Pro Flex for flexible parts (tires, bumper, seat, handles)

 PLA for color details

 PETG for light reflectors

 Pro HT for rigid parts

Nera E-Motorcycle BigRep NOWlab 3D-Printed
Nera illustrates the massive benefits that 3D-printing offers for the production of end-use parts, particularly for batch sizes between lot size one [small quantities manufactured in a single production run] to small series, by reducing lead times and costs, optimising supply chains and limiting dependency on supplier networks"

NOWlab co-founder Daniel Büning

Design features

Fully functional, full scale 3D printed prototype

All parts printed with BigRep printers except electronics, including body, rims, tires, steering, seat, headlight, shocks

Flexible parametric bumper replaces suspension as a shock absorber

Custom fitted seat and chest rest printed with flexible thermoplastic

Airless tires with customized tread printed with flexible thermoplastic

Front tire has an arch structure for a softer, smoother ride

Back tire has a stronger hexagonal structure for load-bearing parts

Electronics fitted in a customizable case

Programmable smart LEDs as headlight, tail light, and accent lights along the body

3D printed light reflectors printed with transparent PETG

Forkless steering with eight pivot points increases joint strength

Lightweight, structurally optimized rhomboid wheel rims

Nera E-Motorcycle BigRep NOWlab 3D-Printed
Nera E-Motorcycle BigRep NOWlab 3D-Printed
Nera E-Motorcycle BigRep NOWlab 3D-Printed
Nera E-Motorcycle BigRep NOWlab 3D-Printed
Nera E-Motorcycle BigRep NOWlab 3D-Printed

The only catch — it's just a "use case" example for a German 3D printing company to show off its material-making skills.

Even if it's not for sale, it's an impressive print job from the NOWlab at 3D printer company BigRep.

Nera E-Motorcycle BigRep NOWlab 3D-Printed

Sure, other electric motorcycles are available to buy and ride, but you won't find many options out there using this many 3D-printed parts.

Print yourself a helmet and you're ready to ride.

Image and Video:  Courtesy of NOWlab / BigRep GmbH
Source: NOWlab

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