Lightning Motorcycle, the San Jose-based electric motorcycle manufacturer, is leveraging the power of artificial intelligence to accelerate its design process. The company has adopted Autodesk's Fusion 360 CAD software, which utilizes AI-based generative design, to develop intricate components significantly faster than traditional engineering methods.
CEO Richard Hatfield highlighted the benefits of this technology, stating that it expands the range of design possibilities beyond the limitations of human experience by accessing a vast database of ideas. This allows engineers to explore a wider array of options and optimize designs for performance and efficiency.
The company initially piloted the software to design a suspension swingarm for an upcoming high-performance version of the Lightning LS-218 superbike. The objective was to create a lighter yet stronger component. The resulting design, described by Hatfield as having an "organic" matrix, achieved a 20% weight reduction compared to the conventional swingarm.
The AI-driven design process involves engineers specifying key parameters, such as length and mounting points, while the software generates multiple iterations. This collaborative approach allows engineers to select the optimal design based on performance and manufacturing considerations.
Beyond weight reduction, the new swingarm also uses less material, contributing to cost savings in both development and production. The initial swingarm design took several months, but the process has been streamlined to just a few days. While the prototype was created using 3D printing and lost wax casting, the first production run will utilize handcrafted tubing, with metal forging being considered for future production.
Hatfield emphasized that the software is trained on fundamental engineering principles, not existing products, eliminating concerns about intellectual property infringement. Lightning Motorcycles anticipates releasing the first bikes equipped with the new swingarm by the end of the year. The company is so impressed with the results that it plans to expand the use of generative AI design across its product development. Hatfield projects that this technology will account for 80-90% of their structural and mechanical engineering design within the next few years.
