Fast and Precise Laser Bevel Cutting of Titanium Tubular Bicycle Parts

With a claim to building the most compact, lightest and safest folding bike yet, Helix Labs, Inc. (Toronto, ON) utilizes innovative manufacturing processes that make its unique design possible. Beyond creating a novel bicycle, Helix made the bold move to automate their manufacturing facilities to meet the demands for cost, quality and consistency. A Laserdyne 430 BeamDirector® fiber laser machining system from Prima Power Laserdyne (Champlin, MN) was a key part of their new process to precisely bevel cut titanium tubing that is used throughout the bicycle. Working closely with Prima Power Laserdyne application engineers, Helix has created a robust, consistently high quality bevel cutting capability based on the 430BDY system. For them, the steeply beveled edges of the titanium tubing required precise and clean cuts to accomplish perfect fit-up of the tubing for accurate robotic welding. The 430BDY system also produces holes and slots in the tubular parts.

But the key is the steep angle bevel cutting of the titanium tubes – a unique 430BDY capability that allowed Helix engineers the flexibility to design the bike assembly for maximum rigidity and strength with the least weight, where other tube cutting systems had limited or no titanium angle cutting capabilities (other competing system suppliers had failed to develop the required robust titanium cutting process). “A key system feature utilizes a horizontally mounted rotary table with a through-bore chuck to accurately locate and hold the titanium tubes for cutting to shape,” explained Corey Hansen, the regional sales manager for Prima Power Laserdyne who helped develop the process. “Titanium is the ideal material for the Helix Bike design because of its high strength, lightweight, remarkable corrosion resistance and unparalleled durability, but it can be challenging to process. The 430BDY produces the beveled cuts up to 45 deg from the surface without dross or spatter residue so tubes mated perfectly ready for the automated welding operations. No secondary deburring or tube cleanup was needed prior to welding.”

Another helpful feature is the integrated control of 6-axis laser motion, allowing Laserdyne application engineers the capability to develop the robust and repeatable process for angle-cutting the titanium tubular components. The 430BDY incorporates the third generation BeamDirector that gives users like Helix a unique capability for not only bevel cutting, but also drilling cylindrical and shaped holes and welding a wide range of materials in addition to titanium, all with the same system. With up to six axes of motion, the system provides the greatest flexibility of any system in its class.

Helix Labs, Inc., Toronto, ON, Canada, hello@helix.ca, www.helix.ca.

Prima Power Laserdyne, 8600 109th Avenue North, #400, Champlin, MN 55316, 763-433-3700, Fax: 763-433-3701, lds.sales@primapower.com, www.primapowerlaserdyne.com.