Sport motorcycle prototype

The sports motorcycle prototype was created for the marketing and advertising of the Zortrax company. The project was to present the possibilities of using 3D printing in the automotive industry to build prototypes. The whole motor was designed in 3D technology and later transferred to a physical motor using prototyping in FDM technology.

The project manager was Piotr Czyżewski who was responsible for implementing the project. From the design of which he is the author himself to the entire organization of the enterprise and the final assembly of the prototype.

The whole prototype was implemented in 2 months.
Sport motorcycle prototype
Sport motorcycle prototype


The whole prototype was based on the existing model. All the parts that made up the motorcycle got rid of. For the needs of the new design, it was necessary to build your own tail and fuel tank construction, thanks to which you could create a new design of the whole motor based on the existing frame, engine, rocker arms and wheels.


The next step was to scan the existing model with 3D scanners. Thanks to this operation, it was possible to go to the stage of creating the project on the scanned parametric model.


The design of the motorcycle was designed on the reworked structure of the existing motorcycle. We had to change tail structures and sleep our own tank. The whole body (fairing), tail frame, tank, seat and lighting were redesigned. A total of 156 printed elements allowed to create a new look of the motorcycle.

Quite futuristic design distinguishes the design from other bikes. The oblong lights at the front together with the mirrors coming straight from the front casing give an aggressive look and improve the aerodynamics of the motorbike. Other characteristic elements are chrome elements on the sides and a chrome structure under the tank and seat.

The aim of the project was to create a sports motorbike based on FDM technologies. The tail has been shortened and the idea of ​​passenger seating has been removed. Also turn signals that are not needed on the track and can have a negative effect on the aerodynamics of the vehicle were not included in the design. The whole block is slim aggressive and apart from sports aspects it also has luxurious aspects like chrome which we rarely see in this type of projects.


The entire Motorbike body was printed using FDM technology. 156 parts were printed, out of which 29 parts constituted the appearance of the motorcycle. Lights and a seat were also printed, which was covered with a sponge and leather. The whole project was printed on 24 printers.


In order for the motor to look like it was pulled out of the salon, all printed elements had to be combined, processed and prepared for painting. We have prepared 24 elements from all 156 printed elements. All elements have been strengthened with a glass mat. After combining the prints, processing and preparing the surface for painting, it was possible to paint all the elements.


Assembling the prototype was the last stage of the project. We had to mount on the motorcycle all the parts that make up the new look, fairings, new tank, seat and lights. It was the most exciting stage, each subsequent part revealed the true nature of this project.


Sport motorcycle prototype


- Development of a conceptual design.
- Conducting an analysis of the choice of technologies and materials.
- Development of a stylistic project.
- Development of a 3D model.
- Development of a 3D CAD model for boat construction.
- Construction of the prototype.


Project completed in 2018