Lead Forensics

Motorbike Performance Optimised by Metrology

Mar 30, 2021 | 3D Scanning, Design, Development

KTM Motorsports have expertly employed metrology instruments, such as 3D scanning and inspection software to look further into their product improvement process.

Firstly, the team used a 3D scanner to capture data for wear and crash analysis on a myriad of different bike components to facilitate their daily quality control (QC) assessment. They also optimised rider positioning and aerodynamic features with 3D scan data by testing and adjusting components during on track testing.

3D measurements for product development and quality control

To maximize the ergonomics and aerodynamics of the bikes, designers and engineers used 3D measurement instruments, that could scan the whole bike, including the rider.

In order to design and produce optimal parts, the KTM team conceives complex shapes, tests them in a wind tunnel or the racetrack, then makes adjustments, tests them again, and so on. While this process can require several iterations, the use of 3D scanners minimized the number of iterations required to achieve the desired specifications as quickly as possible.

One of the benefits of the 3D scanning solution used by KTM is its portability: the 3D scanner can be used in various environments, i.e., bringing the scanning gear to the test racetrack and taking reliable, high-quality, precise measurements to make design decisions in a timely manner. Plus, setting up the equipment for a scan-ready configuration takes virtually no time. Real-time meshing and dynamic referencing are also readily available for data acquisition at the workshop, or at the racetrack.

From a quality control standpoint

Using inspection software, KTM’s quality control team performed wear and failure analysis on frame and chassis components. The outcome was then used to detect areas of design improvement, and to document and monitor component features and deviations that could potentially hinder the performance of the bikes. From a QC standpoint, finding the root cause of such deviations quickly is crucial to draw conclusions and alter the design accordingly.

The ability of the 3D scanner to acquire large amounts of data in a short time echoed with KTM’s READY TO RACE mentality, focused on both speed and performance. Very precise and not necessarily focused on discrete points, the 3D scanner allowed for the measurement of components.

Main Image; copyright Chiba Ragi, used under Creative Commons Licence.


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The PES Scanning blog provides information and news on the scanning and engineering services we offer. The blog also includes views from our team and information about projects we’ve been working on.