FILLAMENTUM MAG #2
Explore a captivating world where high-tech innovation meets the rebellious spirit of custom motorcycles. After seven years of dedicated work, boundless perseverance, and technological breakthroughs, the Scavenger was born — a unique motorcycle that’s more than just a machine. Using 3D printing and recycled materials from Fillamentum, designer Jan Hrbek has crafted a piece that pushes the boundaries of imagination. Scavenger blends post-apocalyptic aesthetics with steampunk charm, showcasing how new technology can give custom design an entirely new dimension.
What Can You Read in the Magazine?
Fillamentum and Scavenger project
The Main News of the Month
Fishy Filaments "0rCA®"
Material of the Month
Electric Motorcycle by František Dvořák
CPE HG100 Case Study
News through the eyes of our expert
3D Printing News
Looking for tips and ideas for the next edition
Fillamentum News
Insights from our team
Petr Paszto | 3D printing specialist
“Most people picture the job of a 3D specialist at Fillamentum as routine laboratory work. The contrary is true though. Every day is full of various challenges, and it resembles the alchemy of the modern age. It requires patience, thorough testing, intuition and searching for the correct applications. This work isn’t about mere printing. It delivers value that companies need to save time and money and always stay ahead in additive manufacturing. I help people achieve better results and at times I feel like I have a superpower. When you work among filaments day after day, eventually you start to see them as colleagues in the office. Each has its own specific characteristics and temperament. I wonder why I don’t sometimes catch them whispering to each other. I constantly think about what material would be suitable for a particular project and sometimes I feel like the filaments respond to me with advice. When the right one takes up a project, something exceptional arises. In our company, I don’t view materials as mere spools of plastic sitting on a shelf. They represent a universe full of possibilities. I can see their potential, waiting for the right moment to become something meaningful. And isn’t that exactly what we ourselves sometimes need? “
The Main News
Written by Gabriela Vašťáková
FILLAMETUM & PROJECT SCAVENGER
Revolutionary Fusion of 3D Printing and Custom Motorcycles
An incredible seven years of development, challenges, and innovation have culminated in a one-of-a-kind project. Jan Hrbek’s custom motorcycle, the Scavenger, is a unique fusion of steampunk style, post-apocalyptic aesthetics, and futuristic elements, created with recycled materials and cutting-edge technology. Supported by Fillamentum, this ambitious project is a prime example of what next-generation materials and 3D printing can achieve.
The Story of the Scavenger: From Idea to Reality
Jan Hrbek’s journey to creating the Scavenger didn’t begin easily—in fact, it was quite the opposite. The vision to create something truly unique and innovative emerged years ago, but as Jan shared with us, the project faced many obstacles along the way.
“It was originally supposed to be a project with a two-year deadline, but I ended up working on it intensively after five years of waiting for unreliable suppliers and external manufacturers of more complex parts. My colleague and I, who was also a motorcycle modifier, decided to create a new project using unconventional methods. Based on an available Ducati Monster model that had a truss frame, I drew the first sketches. When we needed investment, among others, I sent the concept to Pepe Riha, entrepreneur and winner of the 2016 Intercontinental Rally. He was intrigued by the project, provided the funding and thanks to that we were able to buy a Ducati Monster S4R and get to work.”
Design and Technology
The Scavenger is more than just a motorcycle; it’s an artistic project that is revolutionizing custom design. Advanced technologies like 3D printing made it possible to create parts with unique designs and durability that traditional methods could not achieve. Throughout development, design software was used to experiment with shapes and structural elements before physical production began.
Using the Ducati Monster S4R as a base, a 3D model was created, serving as the foundation for the build, which combined modern techniques with traditional methods like metalworking and welding. This process was filled with challenges, including the creation of custom wheels and a fuel tank, which demanded significant time and patience.
A crucial step in making the Scavenger a reality was collaborating with technological partners to leverage modern tools efficiently. Jiří Erban from BlackPrint contributed his expertise in 3D printing complex materials and handled part of the production, greatly expanding the manufacturing possibilities. As Jan Hrbek himself noted, “With 3D printing and new materials, the custom world can enter entirely new dimensions.” This approach has turned the Scavenger into a project that illustrates how innovative technologies can enrich traditional craftsmanship and advance sustainability in design.
Challenges and Creative Solutions
The development of each component for the Scavenger motorcycle came with its own set of challenges. For instance, creating custom wheels with eighteen-spoke rims took several years due to unreliable suppliers and complex manufacturing processes. Similarly, the fuel tank design evolved from the initial concept of using an aluminum barrel—which ultimately failed testing—into the final solution, which utilized a shaped pressure vessel.
The Key Role of 3D Printing
The Scavenger project utilized an innovative carbon-nylon filament called Fishy Filament by Fillamentum 0rCA®, made from recycled fishing nets. This material provides excellent strength and heat resistance, essential for motorcycle parts exposed to high temperatures, such as exhaust components. 3D printing allowed for precise craftsmanship and a unique design that are crucial to both the functionality and aesthetics of the Scavenger.
Additional filaments included materials like PETG, known for its high durability, which enhanced the motorcycle’s overall performance and reliability. Thanks to these modern materials and technologies, it was possible to create components that would be challenging to manufacture using traditional methods, supporting the project’s overall concept and vision.
Scavenger as a symbol of innovation and creativity
The Scavenger project stands as proof of how far modern technologies can advance the world of custom motorcycles. This extraordinary machine combines precise craftsmanship with an eco-conscious approach, reflecting today’s demands for sustainability. Every detail on the Scavenger tells a story of traditional artistry intertwined with advanced technology, creating a truly unique design. The motorcycle was briefly exhibited at OC Galerie Teplice, and we hope it will be showcased at future exhibitions, where it will demonstrate to motorcycle enthusiasts just how far creativity and innovation can go in the custom world.
Main project implementers
Jan Hrbek (@HrbekDesign)
Jan Hrbek is a designer and 3D graphic artist who specializes in architectural design and visualizations for interiors, exteriors, and commercial buildings. However, his true passion has always been automotive and motorcycle design, a field he has pursued since his studies at Czech Technical University (ČVUT). During his education, he was mentored by the legendary figure in Czech industrial design, Václav Král, and later by automotive artist Pavel Hušek, who personally introduced him to icons such as Paolo Pininfarina, Franco Sbarro, and Leonardo Fioravanti.
Among Jan’s notable projects are the transformation of a Honda VT750 Shadow into a unique bobber, the revival of the Böhmerland brand, and the stunning custom design Kamaitaci, which draws inspiration from Japanese culture of the 1980s and sci-fi films like Akira and Blade Runner. The Scavenger is his most recent project, while another long-awaited concept is currently in the pipeline, awaiting its opportunity to be realized.
Josef Říha – Owner
Josef Říha is an entrepreneur with a passion for travel and sports, whether in winter or summer, and he is also a great motorsport enthusiast. He is the winner of the 2016 Intercontinental Rally (Classic category), which covered a 6,000 km route through the Sahara, mirroring the original Paris-Dakar race.
In addition to his sports pursuits, Josef is dedicated to sustainable environmental protection projects in countries such as Congo and Indonesia, where he aims to create self-sustaining models for long-term conservation, ensuring that these initiatives are independent of sponsorships. Josef Říha is a man who not only fulfills his own dreams but also provides opportunities for others to share in those experiences.
Jiří Erban (BlackPrint)
Jiří Erban, the founder of the custom 3D printing workshop BlackPrint, specializes in producing durable replacement parts and specific accessories, primarily for airsoft guns. With many years of experience in 3D printing, his work is highly regarded for its precision and quality. Thanks to his in-depth knowledge of 3D technologies, Jiří is able to create components that often surpass the originals, meeting the demanding standards for both functionality and durability.
Interview
Written by Gabriela Vašťáková
SCAVENGER: BEHIND THE SCENES
Behind the scenes of the Scavenger project lies countless hours of work and creativity that brought to life a revolutionary motorcycle, combining modern technologies with a unique design. In this interview, we gain insight into the 3D printing process and other details through the perspective of Jiří Erban, one of the key contributors to this project. Jiří shares not only the technical challenges he faced but also fascinating stories about his collaboration with designer Jan Hrbek.
Who is Jiří Erban and what do you do?
My role focuses on 3D printing and laser engraving. Since 2018, I’ve been dedicated to 3D printing and do whatever is needed. The main emphasis is on 3D printing, and when I have the opportunity to print something, I gladly take on the task.
How did you get involved in the Scavenger project?
I was invited to the project by Jan Hrbek, whom I have known for quite some time. I had previously assisted him with 3D printing parts for motorcycles. Jan has an incredible talent for modeling and rendering; his models are truly photorealistic. He had ideas for additional motorcycles that we could realize without needing an investor, which gives us creative freedom.
Which parts of the Scavenger motorcycle were 3D printed?
All the fairings, instrument brackets, and light mounts were 3D printed. Essentially, everything that could be printed was done so. What couldn’t be printed was made from metal.
Can you estimate how many hours of printing the project took?
Estimating that is difficult. The project lasted almost two years, during which I was constantly printing and delivering parts. I believe it amounted to hundreds of hours. We also utilized the SLS method, where multiple jobs were printed simultaneously, which added a lot of time to the overall project.
Did you encounter any problems during printing? Did you have to remodel any parts?
Yes, we occasionally ran into issues. Jan is a designer, and sometimes his designs weren’t straightforward to print. For instance, I advised him to avoid rounding some invisible parts, which would simplify the printing process and eliminate the need for supports. In many cases, I didn’t know what the parts would be used for until we clarified it.
What filaments did you use for 3D printing?
We used Orca material for parts close to the engine, nylon SLS, and most of the fairings were made from PETG/CPE.
Orca is a new material. How was your experience printing with it?
At first, I was skeptical about materials with fillers because I need my parts to have high strength. However, when I printed the first parts using Orca, I was pleasantly surprised by their durability. They printed well, although some larger parts were more challenging. We had to adjust the printing parameters to minimize warping.
Do you use any materials from Fillamentum outside of the Scavenger project?
Yes, I print a lot with CPE for parts related to firearms. I often combine CPE and PETG, as well as nylon.
Have you ever kept a list of what has been printed and what materials were used?
I have the models saved, but I don’t have a specific list. I maintain more of a general overview, but that could be useful for the future.
What criteria did you use to select materials for the individual parts?
The main factor was temperature resistance. We discussed where each part would be located and what temperatures it might reach, especially near the engine and exhaust.
What material was used for the most exposed parts?
All heat-exposed parts were mostly made from Orca or nylon, which ensured the necessary durability.
What equipment did you use for printing?
All parts were printed on the Quiddy Max 3 printer, which can reach up to 70°C in the printing chamber.
How did you handle filament moisture during printing?
I printed directly from the dryer, so the filaments were well-prepared and had optimal moisture levels.
Can you summarize what Scavenger represents?
Scavenger is not just a motorcycle; it’s an artistic project that revolutionizes custom design. Thanks to 3D printing, we were able to create unique and durable parts that traditional methods couldn’t achieve. Collaboration with technological partners, including my expertise in 3D printing, expanded production possibilities and contributed to design sustainability. As Jan Hrbek noted, “with 3D printing and new materials, the custom world can be pushed into entirely new dimensions.”
In this way, Scavenger has become a project that demonstrates how innovative technologies can enrich traditional craftsmanship and contribute to sustainability in design.
Material of the Month
Written by Barbora Jurčová
Fishy Filaments by Fillamentum
0rCA®
At a time when plastics are flooding our oceans and environmental pollution is reaching alarming levels, Fishy Filaments offers an innovative solution. This startup from Cornwall, led by Ian Falconer, repurposes fishing nets—single-use nylon material that would otherwise end up in landfills or incinerators. Fishy Filaments not only transforms these nylon nets into high-quality 3D printing materials but also provides a sustainable alternative to traditional carbon fiber composites. The result is the eco-friendly filament OrCA®, which is utilized in demanding industrial and design applications worldwide.
Did You Know that…
The core of the sustainability of Fishy Filaments by Fillamentum extends beyond just cleaning our oceans and seas? A key advantage is the significant reduction in carbon footprint! Most discarded fishing nets end up in landfills, where they are either burned or buried, representing a considerable waste of this advanced material.
By recycling fishing nets into Porthcurno filament, CO2 emissions are reduced by 98% compared to traditional nylon production. For OrCA, the reduction in CO2 emissions is 95%. In this way, we contribute to environmental protection and make efficient use of materials that would otherwise unnecessarily pollute our planet.
The Story of Its Creation
The idea of utilizing fishing nets came to Ian Falconer in 2016, when he recognized the urgent need to address the environmental consequences of waste generated by these nets. This realization led him to establish the startup Fishy Filaments in Cornwall, South England, with the mission of repurposing waste from fishing nets. The company specializes in using nets made from a single type of nylon (polyamide 6 without fillers), which is used worldwide—from small-scale fishermen in India to multi-kilometer nets in open seas.
Each year, up to 200,000 tons of nylon are produced for fishing nets, but they are only actively used for a few months. Of this amount, only 15% is recycled, 1-2% is lost at sea, and the rest is either burned or sent to landfills. This leads to a significant loss of the valuable properties and potential of this technical material.
To tackle this issue, Ian developed a unique process at Fishy Filaments that involves cleaning the nets of salt from seawater, conducting detailed mechanical cleaning to remove impurities, and then grinding the material for further applications. Fishy Filaments offers its material in two main variants: Porthcurno, made solely from fishing nets and featuring an attractive translucent turquoise color, and OrCA®, which is enriched with 10% recycled carbon fibers for enhanced mechanical properties.
Key Properties
Fishy Filaments’ OrCA® is a Nylon 6 material filled with 10% recycled carbon fiber cut strands. Both the nylon and the carbon fibers are recycled, making OrCA® one of the materials with the lowest carbon impact in its class.
It combines the highly beneficial properties of Nylon 6, such as:
- Exceptional temperature resistance up to 180 °C
- Chemical resistance
- High strength and stiffness
The addition of carbon fibers enhances wear resistance and reduces the thermal expansion of the material. Its mechanical properties make OrCA® particularly interesting for applications that require exceptional strength and stiffness, such as:
- Mobility components
- High-speed parts
- Various industrial and design applications
Why Choose OrCA®?
Using Fishy Filaments’ OrCA® is an excellent choice not only from an ecological standpoint but also for practical reasons. Here are the key benefits:
High Temperature Resistance: OrCA® is a highly temperature-resistant material with exceptional mechanical properties.
Durability: It is suitable for prototyping structural components where high wear resistance is essential.
Low Carbon Footprint: For many 3D printing projects, utilizing materials with a low carbon footprint is becoming increasingly important. The production emissions of CO2 per kilogram of Fishy Filaments’ OrCA® are 90% lower compared to conventional nylons.
For those looking to combine sustainability with a high-performance technical material, Fishy Filaments’ OrCA® is the clear choice.
Where OrCA® Has Succeeded
Fishy Filaments’ OrCA® has found applications not only in high-tech uses but also in design products. An example of this is the aforementioned Scavenger project, as well as the Light Pads project for playgrounds by Playerverse, which produces interactive play equipment from this recycled material. These Light Pads are easy to install in children’s play areas and use RFID technology to activate various games, encouraging children to move and have fun.
CPE HG100 Case Study
Written by Ivana “Laila” Drobná
MOTOCYCLE BY F. DVOŘÁK
Let’s revisit an older yet still relevant motorcycle project. In 2018, František Dvořák created a concept for an electric motorcycle as part of his diploma thesis at the University of Technology in Zlín for the Czech company Kuberg. Thanks to advanced technologies, he managed to design and build a functional prototype within nine months. The motorcycle’s body was 3D printed at full scale, taking an impressive 43 days of printing and consuming 2.5 km of CPE HG100 material, chosen for its strength and heat resistance. The project received several awards, including the National Award for Student Design and a special rector’s award from UTB, drawing attention to innovative design in the field of electric motorcycles.
3D Printing News
Written by Petr Pasztó
The Hottest News in the World of 3D Printing Through Our Expert’s Eyes
In the rapidly evolving world of 3D printing, it’s crucial to stay updated on the latest trends and innovations that can significantly impact the industry and everyday life. Our new section, “Petr’s 3D Printing News”, curated by 3D printing specialist at Fillamentum, Petr Paszto, brings you the latest innovations, research, and applications in the field of 3D printing. Let’s take a closer look at what has caught our printer’s attention the most.
Ceramic Filters for Environmental Safety
Researchers at the University of Bath have developed 3D-printed ceramic filters specifically designed to capture and remove harmful “forever chemicals” (e.g., PFAS) from water, achieving up to 75% removal. These filters can be regenerated and reused, positioning them as sustainable solutions for water purification on an industrial scale.
Jaguar Land Rover Advances with 3D Printing in Automotive Production
Jaguar Land Rover is increasingly using 3D printing for rapid prototyping and mass customization to improve vehicle quality and sustainability. This approach supports their goal of reaching net-zero emissions by 2039, while simultaneously expediting the development of new car models.
Holographic 3D Printing for Medical and Automotive Fields
Researchers at Concordia University have developed a pioneering holographic 3D printing method, which could transform applications in medicine and automotive manufacturing. This technique uses unique optical processing to create intricate structures with potential in high-precision fields
Elkem Launches Medical-Grade Silicone for 3D Printing
At Formnext 2024, Elkem plans to reveal new silicone materials designed for Liquid Deposit Molding (LDM) technology, ideal for healthcare applications. These materials offer increased durability and adjustable hardness, catering to precise medical specifications.
Microstructured Materials for Bioprinting
A breakthrough in printing complex microstructures shows promise for bioprinting, particularly for creating cell-based constructs and implants. This method aims to better mimic natural tissue properties, advancing the field of tissue engineering. (Researchers at Concordia).
FDA Green-Lights Multi-Material Dentures
3D Systems gained FDA approval for their MultiJet Printing system to produce multi-material dental prostheses. These 3D-printed dentures offer increased strength and visual quality, modernizing options for dental laboratories and enhancing patient comfort.
Bioprinted Lung Tissue
Frontier Bio has achieved significant progress in developing lab-grown lung tissue using bioprinting techniques combined with stem cells. The lab-grown tissue mimics natural lung functions, like mucus production, and opens new possibilities for respiratory disease treatments, drug testing, and potentially future organ transplants.
News from Fillamentum
Written by Martin Opustil
Share Your Tips for This Year's Holidays
The holiday season is just around the corner, and we would like to dedicate our December issue of 3D printing to a festive theme. If you have tips for great projects, favorite 3D models, or unique holiday decorations that should not be missed in the magazine, let us know! You can send us links to STL models, upload your own images, or share interesting ideas that will inspire other readers. We look forward to your contributions—perhaps your suggestion will help fellow readers create the perfect holiday atmosphere.
The magazine will be released on December 4th, so don’t hesitate and send in your ideas as soon as possible!
