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Making the Light Rider (10/25) Support structure removal: The dirty secret of AM is support structures, which are critical to the quality of the part produced. They need to be designed just strong enough to anchor the part, but weak enough to be removed easily in post-processing.

Making the Light Rider (11/25) Bench Work: Contrary to popular belief, a lot of labour goes into removing supports and 'fettling' the surfaces of the part. Note the array of tools in the background! Now the main components of the frame come together for a fit check.

Making the Light Rider (12/25) After 9 builds, and delivery of the bought-in components, all of the individual pieces of the Light Rider are starting to come together. The next step is to prepare them for welding and assembly.

Making of the Light Rider (13/25) Pre-welding preparation: All of the weld locations are manually checked and dressed to ensure a good fit for jigless assembly, and the adjacent surfaces are hand smoothed to make them easy to de-contaminate prior to welding.

Making the Light Rider (14/25) Coming Together: Yes that's right, still more bench work to get everything to fit neatly together prior to welding, but it is starting to look like a frame, and a pretty gnarly one too...

Making the Light Rider (15/25) Welding the frame: Scalmalloy can be welded succesfully using TIG (Tungsten Inert Gas). Interesting fact - 'TIG' is called 'WIG' here in Germany, because Tungsten is Wolfram in German. This is also why the chemical symbol for Tungsten is 'W'.

Making the Light Rider (16/25) Completed welded assembly: Now here is the really exciting part. The Scalmalloy frame comes together as a fully welded assembly and the vision of our engineers starts to become a reality! apworks.de

Making the Light Rider (17/25) Assembly: We start to assemble all of the other components to the Scalmalloy frame. An advantage of using Additive Manufacturing is the ability to adapt the design to interface with the available off-the-shelf components. apworks.de

Making the Light Rider (18/25) Assembling all the components to the frame turns this skeletal work of art into a 'living' motorcycle, but along the way it did resemble some other living things. Does this remind you of anything? Share your thoughts in the comments ;-)

Making the Light Rider (19/25) Details like the handlebar stem adaptor make the bike both functional and eyecatching. In this case the finish was kept raw, but did you know that Scalmalloy can also be etched and anodised with excellent results? apworks.de/scalmalloy

Making the Light Rider (20/25) We are teasing you a little now, just to emphasise the effort involved in building up a working bike. The Scalmalloy frame is the eye-catching centrepiece, but the attention to detail is key, and is where the most effort lies.

Making the Light Rider (21/25) Now it really looks like a bike... although with quite a few critical pieces still missing. But it is possible to sit on it, and of course everyone wants to try it out. Niels looks pretty happy in this picture!

Making the Light Rider (22/25) Now the motor, battery system and controller are all installed, and the bike is ready to be tested. It looks just as cool as the first concept renders, and it is hard to believe it is real!

Making the Light Rider (23/25) A few more gratuitous shots of the bionic Scalmalloy frame structure, before we twist the throttle and go!

Making the Light Rider (24/25) Ready to race, the Light Rider looks like something out of a Scifi film, but it is very real and quite a head turner. If you want to design and build products like this, then see if you can be a part of our team: apworks.de/careers

We are excited to be able to share with you an insight into some of our in-house software developments which are enabling more automated engineering and manufacturing workflows for custom components. Join us at the NAMIC Global AM Summit 2021. linkedin.com/posts/namicsg_…

Join us and hear insights from over 20 global Additive Manufacturing (AM) experts at NAMIC Global AM Summit 2021! Sign up: namic.tv #AdditiveManufacturing #3Dprinting #Investment #EmergingApplications #Sustainability #GlobalSupplyChain #GAMS2021

Learn more about Scalmalloy and how it is enabling the space sector apworks.de/scalmalloy-thr…

Are you curious? A problem solver? Do you like helping others? Interested in applying the latest in engineering and manufacturing technology to help our customers solve their problems in new and better ways? Join the A-Team: apworks.de/careers

Are you curious? A problem solver? Do you like helping others? Interested in applying the latest in engineering and manufacturing technology to help our customers solve their problems in new and better ways? Join the A-Team: apworks.de/careers