Inexpensive, Lightweight Motorcycle Aluminum Frames with High Design Appeal

Aluminum frames made with our CF die-casting technology

Lighter weight
Higher rigidity
Higher precision
Design appeal
Cost reduction

Our CF (controlled filling) die-casting technology yields a number of benefits, such as higher vacuum degree in the mold cavity, precise control of mold temperature, and higher melt injection (flow) speed. We also developed a special release agent to facilitate separation of the finished casting, and all of these led to a significant reduction in gas porosity defects in the cast aluminum piece. Further, CF die casting enables us to create lighter, more rigid castings with high design appeal while also reducing manufacturing costs. In comparison, the frame of a previous motorcycle model made of steel pipe was composed of 88 individual parts, required 9 m of welding, and weighed 22.5 kg. The latest CF die-cast frame consists of only 7 parts, requires no welding at all, and weighs only 13.8 kg.

Need: Aluminum motorcycle frames with greater engineering and design freedom that are high in performance but low in cost

DevelopmentDirection #1: Reduce the number of parts to raise manufacturing efficiency and lower costs

DevelopmentDirection #2: Achieve high dimensional precision even with large parts with thin sections

DevelopmentDirection #3: Achieve lower weight and higher rigidity while providing greater freedom for engineering and design

Solution

01CF Aluminum Die-Casting Technology

Yielded higher vacuum degree in the mold cavity, precise control of mold temperature, and higher melt injection (flow) speed. Also developed a special release agent

02Die Casting Material Development

Developed aluminum alloys and other base materials for die casting for greater toughness, strength, etc.

03Die-Casting Technologies

Reduced the volume of gas porosities and enabled welding of cast pieces to each other

Using ADC3 (Silafont36) for high strength and toughness

Result

	2003 model	2004 model	2020 model
Frame construction	Steel pipe + welding	CF die casting Steel pipe + welding	CF die casting
Number of parts	88	31	7
Length of welds	9m	2.9m	0m
Frame weight	22.5kg	16.8kg	13.8kg

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