Case Study: Krause DiMaTec achieves 55% lighter e-bike motor mount with Hexagon generative design

Generative design provides an easy ride for e-Bike manufacturer with 55% lighter design for additive manufacturing

Krause DiMaTec GmbH, an industrial 3D printing expert, was challenged by bicycle manufacturer Xplorcycles to redesign a heavy motor mount for its recumbent bicycles. The existing design was unsuitable for additive manufacturing and added excessive weight. Krause DiMaTec partnered with Hexagon and leveraged its MSC Apex Generative Design software to develop a new, lightweight geometry optimized for 3D printing.

Using Hexagon's software, the team generated a bionic design from scratch based on 17 real-world load cases. The solution resulted in a motor mount that was 55% lighter and 90% less deformed under load than the original, while also eliminating the need for additional adapters. The part was successfully manufactured and installed without post-processing, leading to a robust, high-quality component ready for series production.

Krause DiMaTec GmbH

Johannes Tominski

Managing Director