3D Printing

EDAG Light Cocoon concept employs weatherproof textile skin over a bionically-inspired, back-lit trellis frame

EDAG Light Cocoon concept empl...
Weight is the enemy of almost all things enjoyable about motoring: acceleration, braking, efficiency, handling and brain-crushing cornering G-forces. This textile-skinned solution means that you don't need to endure the spartan hardships of an Ariel Atom to get motorcycle-like performance or economy on four wheels.
Weight is the enemy of almost all things enjoyable about motoring: acceleration, braking, efficiency, handling and brain-crushing cornering G-forces. This textile-skinned solution means that you don't need to endure the spartan hardships of an Ariel Atom to get motorcycle-like performance or economy on four wheels.
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Weight is the enemy of almost all things enjoyable about motoring: acceleration, braking, efficiency, handling and brain-crushing cornering G-forces. This textile-skinned solution means that you don't need to endure the spartan hardships of an Ariel Atom to get motorcycle-like performance or economy on four wheels.
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Weight is the enemy of almost all things enjoyable about motoring: acceleration, braking, efficiency, handling and brain-crushing cornering G-forces. This textile-skinned solution means that you don't need to endure the spartan hardships of an Ariel Atom to get motorcycle-like performance or economy on four wheels.
The EDAG Group has elucidated its target in this process as: "to develop and present practicable and valid applications for use in component development and production. The first stage will be small structural parts; however, we intend to make a real contribution to the development of the revolutionary idea of additive manufacturing." The GENESIS is another example of biomimicry - solving complex engineering problems by imitating solutions provided by nature
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The EDAG Group has elucidated its target in this process as: "to develop and present practicable and valid applications for use in component development and production. The first stage will be small structural parts; however, we intend to make a real contribution to the development of the revolutionary idea of additive manufacturing." The GENESIS is another example of biomimicry - solving complex engineering problems by imitating solutions provided by nature
EDAG’s genX show car had inbuilt suitcases and a bed to cater for “the modern lifestyle” - having a bed without having to drive home, being able to drink without having to drive or sleeping in your car permanently. The genX premiered at the 2004 Geneva International Motor Show.
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EDAG’s genX show car had inbuilt suitcases and a bed to cater for “the modern lifestyle” - having a bed without having to drive home, being able to drink without having to drive or sleeping in your car permanently. The genX premiered at the 2004 Geneva International Motor Show.
If there has been a common thread to Gizmag's twelve years of editorial coverage of technological development in all sectors, it has been that there is ALWAYS a better way, and it's coming soon. EDAG's Genesis is a prime example, as is the "Light Cocoon"
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If there has been a common thread to Gizmag's twelve years of editorial coverage of technological development in all sectors, it has been that there is ALWAYS a better way, and it's coming soon. EDAG's Genesis is a prime example, as is the "Light Cocoon"
If there has been a common thread to Gizmag's twelve years of editorial coverage of technological development in all sectors, it has been that there is ALWAYS a better way, and it's coming soon. EDAG's Genesis is a prime example, as is the "Light Cocoon"
5/18
If there has been a common thread to Gizmag's twelve years of editorial coverage of technological development in all sectors, it has been that there is ALWAYS a better way, and it's coming soon. EDAG's Genesis is a prime example, as is the "Light Cocoon"
ROW-BY-ROW, RIGHT-TO-LEFT: Some of EDAG's previous showcars include the genX for those who prefer to be of no-fixed-address, the Show Car No. 8 from 2005, the marine concept LUV luxury SUV, a removable hardtop for the Pontiac Solstice which turned it into a Shooting Brake, the 2009 open-source Light Car, the BIWAK Volkswagen Beetle Estate Car of 2006, the Porsche-based Chopster, the EDAG Scout of 1999, and the Cinema 7D "cinema on wheels" from 2005.
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ROW-BY-ROW, RIGHT-TO-LEFT: Some of EDAG's previous showcars include the genX for those who prefer to be of no-fixed-address, the Show Car No. 8 from 2005, the marine concept LUV luxury SUV, a removable hardtop for the Pontiac Solstice which turned it into a Shooting Brake, the 2009 open-source Light Car, the BIWAK Volkswagen Beetle Estate Car of 2006, the Porsche-based Chopster, the EDAG Scout of 1999, and the Cinema 7D "cinema on wheels" from 2005.
The structures are generated by having robots apply thermoplastic materials. Complex structures are built up layer by layer in an open space - without any tools or fixtures whatsoever.
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The structures are generated by having robots apply thermoplastic materials. Complex structures are built up layer by layer in an open space - without any tools or fixtures whatsoever.
The structures are generated by having robots apply thermoplastic materials. Complex structures are built up layer by layer in an open space - without any tools or fixtures whatsoever.
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The structures are generated by having robots apply thermoplastic materials. Complex structures are built up layer by layer in an open space - without any tools or fixtures whatsoever.
Unlike other technologies, FDM makes it possible for components of almost any size to be produced, as there are no pre-determined space requirements to pose any restrictions.
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Unlike other technologies, FDM makes it possible for components of almost any size to be produced, as there are no pre-determined space requirements to pose any restrictions.
In the assessment, a specially developed evaluation matrix was used to quantify the technologies; this included criteria such as structural relevance, possible part size, production tolerance and manufacturing costs. The results showed that a refined FDM process also looked to be a promising candidate for the future-oriented subject of additive manufacturing.
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In the assessment, a specially developed evaluation matrix was used to quantify the technologies; this included criteria such as structural relevance, possible part size, production tolerance and manufacturing costs. The results showed that a refined FDM process also looked to be a promising candidate for the future-oriented subject of additive manufacturing.
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
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I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
12/18
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
13/18
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
14/18
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
The Light Cocoon also opens an entirely new realm in automotive aesthetics with the backlight technology illuminating the underlying organic skeleton-like structure. In a world that quite literally has more than a billion same-same automobiles, the "EDAG Light Cocoon" might inspire some interesting creations in the not-so-distant future.
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The Light Cocoon also opens an entirely new realm in automotive aesthetics with the backlight technology illuminating the underlying organic skeleton-like structure. In a world that quite literally has more than a billion same-same automobiles, the "EDAG Light Cocoon" might inspire some interesting creations in the not-so-distant future.
Last year when we flight tested the 300 hp Seabreacher X, we put together this table of the power-to-weight ratios of the most ballistic toys available to mankind at that time. Quite clearly, the Ariel Atom V8 punches way above its price category. Not many four-wheelers are capable of getting the front wheels off the ground under acceleration, as the below photo attests.
16/18
Last year when we flight tested the 300 hp Seabreacher X, we put together this table of the power-to-weight ratios of the most ballistic toys available to mankind at that time. Quite clearly, the Ariel Atom V8 punches way above its price category. Not many four-wheelers are capable of getting the front wheels off the ground under acceleration, as the below photo attests.
The naked Ariel Atom V8 might finally be able to offer some protection from the elements.
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The naked Ariel Atom V8 might finally be able to offer some protection from the elements.
The 300 hp Seabreacher X, another example of bio-engineering based on a 400 million year-old design. Sharks existed before land vertebrates (they're twice as old as the dinosaurs), first appearing in the oceans somewhere between 450 and 420 million years ago, so nature has had quite some time to refine its top-of-the-food-chain model. With the motor upgraded from approximately one horsepower to 300, it's quite a weapon.
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The 300 hp Seabreacher X, another example of bio-engineering based on a 400 million year-old design. Sharks existed before land vertebrates (they're twice as old as the dinosaurs), first appearing in the oceans somewhere between 450 and 420 million years ago, so nature has had quite some time to refine its top-of-the-food-chain model. With the motor upgraded from approximately one horsepower to 300, it's quite a weapon.

EDAG traditionally produces a concept car incorporating "new thought" for the Geneva Motor Show each year and the 2015 concept car might initially stretch your imagination beyond "business as usual." The EDAG Light Cocoon Concept uses a weatherproof textile instead of the traditional metal skin for the car's panels, stretched over a bionically-inspired trellis body structure, then back-lit for effect.

Alongside Rinspeed, EDAG's concept cars are the most fun of all regular concepts to write up - they invariably push the boundaries of what's possible, and they're always using new techniques and technologies which are viable or soon-to-be viably incorporated in our transportation devices.

ROW-BY-ROW, RIGHT-TO-LEFT: Some of EDAG's previous showcars include the genX for those who prefer to be of no-fixed-address, the Show Car No. 8 from 2005, the marine concept LUV luxury SUV, a removable hardtop for the Pontiac Solstice which turned it into a Shooting Brake, the 2009 open-source Light Car, the BIWAK Volkswagen Beetle Estate Car of 2006, the Porsche-based Chopster, the EDAG Scout of 1999, and the Cinema 7D "cinema on wheels" from 2005.
ROW-BY-ROW, RIGHT-TO-LEFT: Some of EDAG's previous showcars include the genX for those who prefer to be of no-fixed-address, the Show Car No. 8 from 2005, the marine concept LUV luxury SUV, a removable hardtop for the Pontiac Solstice which turned it into a Shooting Brake, the 2009 open-source Light Car, the BIWAK Volkswagen Beetle Estate Car of 2006, the Porsche-based Chopster, the EDAG Scout of 1999, and the Cinema 7D "cinema on wheels" from 2005.

Regular Gizmag readers will no doubt remember the EDAG Genesis, from earlier this year which we billed as the "3D printed car of the future."

The EDAG Genesis employed biomimicry, essentially solving complex engineering problems by imitating solutions provided by nature. In the case of the GENESIS, it used the turtle's shell as the central concept in providing protection and cushioning for the occupants of an automobile, then used 3D printing to create the design and give us a 3D visualisation of what the world's leading manufacturers might be producing a decade or two from now.

The EDAG Group has elucidated its target in this process as: "to develop and present practicable and valid applications for use in component development and production. The first stage will be small structural parts; however, we intend to make a real contribution to the development of the revolutionary idea of additive manufacturing." The GENESIS is another example of biomimicry - solving complex engineering problems by imitating solutions provided by nature
The EDAG Group has elucidated its target in this process as: "to develop and present practicable and valid applications for use in component development and production. The first stage will be small structural parts; however, we intend to make a real contribution to the development of the revolutionary idea of additive manufacturing." The GENESIS is another example of biomimicry - solving complex engineering problems by imitating solutions provided by nature

Of all the technologies to have emerged from the digital renaissance, additive manufacturing (3D printing) has the potential to be the most disruptive.

From EDAG's March 2014 media release: "The framework of the exhibit calls to mind a naturally developed skeletal frame, the form and structure of which should make one thing perfectly clear: these organic structures cannot be built using conventional tools! In the future, additive manufacturing (3D printing) could benefit designers and engineers by opening up enormous freedoms and new design options for development and production."

In the assessment, a specially developed evaluation matrix was used to quantify the technologies; this included criteria such as structural relevance, possible part size, production tolerance and manufacturing costs. The results showed that a refined FDM process also looked to be a promising candidate for the future-oriented subject of additive manufacturing.
In the assessment, a specially developed evaluation matrix was used to quantify the technologies; this included criteria such as structural relevance, possible part size, production tolerance and manufacturing costs. The results showed that a refined FDM process also looked to be a promising candidate for the future-oriented subject of additive manufacturing.

The Genesis was more a conceptual sculpture than an automobile, but the "EDAG Light Cocoon" takes it one step further and gives us a full concept study of a compact, dynamic sports car, and a realistic idea of what future lightweight construction might look like.

Using the same principals as the Genesis, EDAG's engineers have expanded their vision of a bionically-optimised body structure combined with a weatherproof textile outer skin.

In order to be able to implement bionic construction principles and natural strategies, additive manufacturing (3D printing) has also been put to use.

"We are pursuing the vision of sustainability – as demonstrated by nature: lightweight, 
efficient, and without any waste," explains EDAG's head designer, Johannes Barckmann.

"The result: the 'EDAG Light Cocoon' presents a stable, branch-like load bearing structure from the 3D printer, which only uses material where it is absolutely necessary."

Instead of treating the body as a closed surface, any material not actually needed for the special load cases was removed. EDAG's simulation experts carried out static and dynamic calculations for the basics of this topologically optimised ideal structure, and in this way helped to confirm its suitability as a potential lightweight concept.

The EDAG designers took a leaf as their inspiration for the ultimate, lightweight outer skin. Just as with a leaf, which has an ideal structure with a lightweight outer skin stretched over it, a textile skin covers the "EDAG Light Cocoon".

The Light Cocoon also opens an entirely new realm in automotive aesthetics with the backlight technology illuminating the underlying organic skeleton-like structure. In a world that quite literally has more than a billion same-same automobiles, the "EDAG Light Cocoon" might inspire some interesting creations in the not-so-distant future.
The Light Cocoon also opens an entirely new realm in automotive aesthetics with the backlight technology illuminating the underlying organic skeleton-like structure. In a world that quite literally has more than a billion same-same automobiles, the "EDAG Light Cocoon" might inspire some interesting creations in the not-so-distant future.

The Light Cocoon also opens an entirely new realm in automotive aesthetics with the backlight technology illuminating the underlying organic skeleton-like structure. In a world that quite literally has more than a billion same-same automobiles, the "EDAG Light Cocoon" might inspire some interesting creations in the not-so-distant future.

I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio

I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio

Last year I flight tested the 300 hp Seabreacher X, another example of bio-engineering based on the shark, and I put together this table of the power-to-weight ratios of the most ballistic toys available to mankind at that time.

Last year when we flight tested the 300 hp Seabreacher X, we put together this table of the power-to-weight ratios of the most ballistic toys available to mankind at that time. Quite clearly, the Ariel Atom V8 punches way above its price category. Not many four-wheelers are capable of getting the front wheels off the ground under acceleration, as the below photo attests.
Last year when we flight tested the 300 hp Seabreacher X, we put together this table of the power-to-weight ratios of the most ballistic toys available to mankind at that time. Quite clearly, the Ariel Atom V8 punches way above its price category. Not many four-wheelers are capable of getting the front wheels off the ground under acceleration, as the below photo attests.

Quite clearly, the Ariel Atom V8 punches way above its price category. Not many four-wheelers are capable of getting the front wheels off the ground under acceleration, as the below photo attests.

I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio
I can't help but think of one of my all-time favourite automobiles when I look at the Light Cocoon: the Ariel Atom. Using a naked trellis frame that's not all that dissimilar to the Light Cocoon, the Atom achieves a preposterous power-to-weight ratio

Weight is the enemy of almost all things enjoyable about motoring: acceleration, braking, efficiency, handling and brain-crushing cornering G-forces. This textile-skinned solution means that you don't need to endure the spartan hardships of an Ariel Atom to get motorcycle-like performance or economy on four wheels.

Now the effectiveness of the solution quite clearly depends on the effectiveness of the skin, and outdoor specialists Jack Wolfskin became a partner in the project due to that company's development of the synthetic outdoor textile known as Texapore Softshell.

"In Jack Wolfskin,the ideal project partner was found to supply a tried and tested stretch fabric that is also extremely weatherproof", said EDAG CTO Jörg Ohlsen.

"Even if it sounds futuristic to begin with, this approach has a its own special appeal: weighing no more than 19 g/m², the Jack Wolfskin material supports maximum lightweight design requirements with minimum weight.

"To give you a comparison: this extremely strong material is four times lighter than standard copier paper. Combined with the topologically optimised, additively manufactured structure, it offers enormous potential and stimulus for the ultimate lightweight construction of the future."

TEXAPORE (English) | Jack Wolfskin

3 comments
Martin Hone
Interesting, but not for the example shown here. This form of covering structures has been used since before the Wright bros. initially A-grade cotton shrunk with 'dope' and later with heat shrunk dacron synthetic fibre. This technique is still in use under the Polyfibre name, and virtually all rag and tube aircraft use it over alloy or chrome-moly steel tube frames or alloy or wood wings. For me, the interesting part is that by my calculation, at 19g/sq.m it is heaps lighter than Polyfibre at around 2.7 oz/sq.ft. OTOH, application of paint may bring the difference back ...
Ben Crumpacker
The frame biodesign is new; the fabric concept is old, updated with new material science. In the 1920s many cars, including some Bentleys, had bodies with painted fabric stretched over wood or metal frames. I do like the concept of lighting such bodies from within so you can change colors, do so continuously fast or slow, or use strobes to make a REALLY flashy car.
The Skud
But how would it (the fabric) cope with truck wheel spat sharp road chips? And I wonder how much of the body / frame would need new 3D printing and replacement after a minor fender-bender?