In partnership with Carboni and Metalli, Bercella creates an innovative motorcycle using composite components and HandySCAN 3D
In Italy, many companies have been created thanks to the dreams and visions of people convinced of their own ideas. In the early 1990s, Franco Bercella dreamed of creating an extremely light aircraft. So he set out to learn more about composite materials. But designing a plane wasn't enough - he also wanted to build it. Franco wasn't deterred by a few details. For example, when he decided to build the factory in which his ultra-light aircraft would be produced. The company was founded in 1996 with the aim of improving the production of structures used in advanced applications. Today, the company's main sectors are automotive, aerospace, defense and rail transport. Over the years and thanks to an ongoing program of research and development, Bercella has acquired extensive experience in the production of composite and light-alloy structures for the aerospace, defense and automotive industries, through the design of innovative and constantly evolving solutions.
Thanks to the integration of these exclusive production capabilities with an impeccable design service, Bercella has become a solid and reliable partner to its customers.
The LUNAR project
A recent partnership with Carboni e Metallian innovative start-up based in Parma, Italy, has created the Lunar project: a motorcycle that combines composite materials produced by Bercella with metal materials produced by additive manufacturing. For example, the fuel tank is made of carbon fiber: a demanding and laborious process, from the design of the model to the production of the mold, right through to the production of the final component.
Right from the start of the process, every step is subjected to the strictest controls. Bercella has adopted a philosophy that could easily be defined as "the price of quality": it is more advantageous to invest in quality controls during the production process, than to waste time and money reworking a defective product or having the customer return the components.
The model was subjected to stringent quality control requirements using Creaform's HandySCAN 3D.. Before the model could be used to laminate the mold, its dimensions were checked and compared with the reference 3D model, using high-definition CAD scan files. The same process was repeated with the mold, then with the final tank. In the end, this seemingly long and complex workflow saves time. With the assurance that every step in the component production process is carried out according to the "price for quality" philosophy, work between the various partners is facilitated.
Creaform 3D's HandySCAN 3D was the best option for rapidly reproducing all the components produced for the Lunar project. For this reason, Bercella placed total confidence in the HandySCAN 3D, an essential tool for their daily work processes.
Bercella used the HandySCAN 3D and VXelements for data acquisition. Not only does HandySCAN 3D offer the best performance for fast, reliable component analysis, it also enables rapid import into CAD programs. The ease with which scan results can be compared with CAD model geometry is an essential aspect in selecting the best inspection method. This feature has proved very important for many projects, where basic measurement techniques were not suitable or sufficient to obtain accurate results.
Bercella also relies on a CMM and optical 3D scanner (with blue-light technology). These two technologies, along with the HandySCAN 3D, can be used separately or together, depending on the specific needs of each project (e.g. part size, required precision, different materials, etc.).
In recent years, rather than replacing individual systems and technologies, Bercella has integrated solutions that already existed within the company. This has enabled a more dynamic approach: in the event that several systems are not available, there is always a back-up solution. Creaform became part of this scenario, reinforcing the company's ability to meet the highest market standards, for both customers and the company.
Why choose Creaform technology?
The company needed a fast, accurate tool for measuring and checking small and medium-sized components, and evaluated a wide variety of solutions. Of these, Creaform proved to be the most promising technology, thanks to its reliability and ease of use.
More specifically, the Lunar project involved parts with complex geometry, requiring 3D reconstruction to verify dimensions, which other standard tools could not detect quickly and economically. Bercella's main objective is to give their customers the peace of mind they expect. Like guaranteeing the quality of not only the products, but also all the checks carried out, in line with requirements.
Apart from the fact that the HandySCAN 3D stands out from its competitors for its portability and flexibility, it is also used by Bercella exclusively in a control room, where parameters such as humidity and temperature are constantly monitored. So, under any conditions, the components to be digitized are kept in a controlled environment. This is an internal requirement that Bercella has established for the control of all components, instruments, masks and molds. This also applies to production conditions, since composite components are produced in clean rooms, where temperature, humidity and even air particles are controlled.
Creaform technologies to save time and money
Time savings also mean shorter lead times. Keeping components in-house, rather than passing them on to partners, means greater control over production. Inspections are carried out each time a component re-enters the factory, which takes time and has repercussions on logistics and systems schedules.
Thanks to Creaform's technology, Bercella has increased its confidence levels in two important areas, control and production: defects or problems can be detected quickly, enabling all risks to be mitigated in the best possible way.
Massimo Bercella, Bercella's Sales Manager, explains: " We look forward to working with Creaform in the future. We firmly believe that it is possible to see the results of a partnership when the buyer/seller relationship is taken to the next level. We will always need reliable technology to control parts and components, so the support of a partner like Creaform is essential. ".