The Energica Ego

In Modena, the first Italian electric motorcycle has been created by using F1 Technologies and the latest 3D printing methods.

Designed and built by the CRP Group, the Energica Ego is an all electric bike which produces 195 Nm torque from 0 RPM to redline, an electronically limited 150 Mph (240 km/h) and a 0 – 100 time of under 3 seconds. The bike has a range of approximately 120 miles and will recharge to 85% in just 30 minutes. The bike is also equipped with a KERS braking system that allows it to recover useful energy for use by the motorcycle like F1 cars.

Selective laser sintering technology and polyamide-based materials reinforced with carbon fibres, called Windform, have been used in the construction of the bike. The laser selectively fuses powdered material by scanning cross-sections generated from a 3D digital file’s description of the part onto the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one indexed layer thickness, then a new layer of material is applied on top, and the process is repeated until the part is completed. Thanks to this technology it is possible to create fairings, headlight covers and motorcycle components apart from the mechanical and electrical parts.

In a short time, 3D Printing and Windform materials can lead to the production of prototypes and functional parts, that once made, can be metalled and painted. With free-form design, short fabrication time and the ability to build extremely complex geometry that cannot be easily tooled (or impossible to tool) a customised production is realised that goes beyond the aesthetic model.

The bike will be available to purchase in 2015 with ABS manufactured with traditional production methods. The 3D-printed parts made from Windform, will be made when the technology advances so that mass-production can become a reality. All metal parts such as the engine frame, the forks and the battery pack will be built with casted aluminium.

The company will also market a prototype version of the bike without the fairing, this model is built with 3D printing and Windform materials and is currently in the research and development phase.