In the event of a puncture during a rally competition, the crew has to provide autonomously to wheel change: it is necessary to be equipped with a fast jack that can lift the car safely.

The challenge for our team was to create a fast and ergonomic product that would satisfy certain characteristics: low weight, low cost equipment, lifting speed and ease of use in compliance with the basic safety requirements.

After over a year of work and several prototypes the result has been EVOjack, still considered the best professional jack for rally use.

Over the years we have realized different projects in the field of sports bike: stems, appendices for time trial handlebars, saddle fixing and cranks.

The studies have included a part of design and engineering development, defining the style or starting from a base provided by the customer, with the technical specifications and project requirements defined and discussed together with the customer’s technical department.

We have carried out FEA / FEM analysis by simulating different kinds of use and performed the laboratory tests for the internal approval or in accordance with the various regulations TUV and DIN, ISO and UNI.

Particularly sensitive to cutting (shearing effect), the carbon tube of the saddle support has been analyzed in detail to eliminate any critical point.

The customer required to redesign the airbox, made of a plastic rubber material, to allow the assembly of a different type of suspension that was into interference with the existing model.

Firstly, starting from a sample made of resin provided by the customer, we used the reverse engineering to obtain a 3D model; then we optimized the steps of the various components of the bike, assembling the piece in the 3D model of the bike. Finally, we obtained the correct thickness, optimized the fixing and made a sample in rapid prototyping for the final check on the actual prototype.

The customer required to redesign the airbox, made of a plastic rubber material, to allow the assembly of a different type of suspension that was into interference with the existing model.

Firstly, starting from sample made of resin provided by the customer, we used the reverse engineering to obtain a 3D model; then we optimized the steps of the various components of the bike, assembling the piece in the 3D model of the bike. Finally we obtained the correct thickness, optimized the fixing and made a sample in rapid prototyping for the final check on the actual prototype.

We realized as many as 18 different components – both structural and aesthetic – of a motorbike prototype for the presentation at a motor show.

The customer had provided some handmade pieces, from which we obtained 3D models using reverse engineering; whereas we designed other details directly in 3D. After creating the individual pieces, we added them to the assembly of the bike in order to verify the dimensions and the mechanisms. We then used the surfaces obtained to create prototype molds with which we realized some mini-series of pieces in plastic and carbon fiber.

The aluminum pieces were milled from solid through rapid CNC machining center.

Despite the tight deadlines and the limitation of the available resources, the project succeeded with great satisfaction for the customer and our entire team.