Harley-Davidson’s Factory Racing team is leveraging Protolabs’ rapid digital manufacturing capabilities to dominate the King of the Bagger racing series. The partnership enables the team to shave crucial seconds off lap times by producing lightweight performance parts between weekly races. With touring bikes modified to reach speeds exceeding 180 mph, the ability to quickly iterate designs has proven vital in transforming 960 lb production motorcycles into competitive 620 lb racing machines.
From Track Data to Finished Parts in Days
The collaboration’s success hinges on Protolabs’ ability to turn race data into functional components within the tight window between events. “We prototype, test, and receive final parts before the next race,” explained Jason Kehl, Harley-Davidson’s racing boss. One breakthrough came through a 3D printed exhaust system that improved lean angles – each additional quarter degree saving a tenth of a second per corner. With some tracks featuring 14 turns per lap, these incremental gains accumulate into significant advantages over competitors.
Engineering Freedom Meets Racing Demands
Protolabs’ additive manufacturing capabilities have unlocked new design possibilities for the racing team. The organic shapes achievable through 3D printing allowed engineers to reposition components closer to the bike’s frame while maintaining rider ergonomics. This design flexibility proved particularly valuable for the bulky touring motorcycle platform, where conventional manufacturing constraints previously limited performance optimization. The digital workflow also accommodates various production methods – from CNC machining to injection molding – tailored to each component’s specific requirements.
Comprehensive Manufacturing Support
Beyond 3D printing, Protolabs provides the team with:
- Precision machined components for critical systems
- Injection molded parts for consistent quality
- Sheet metal fabrication for structural elements
For larger assemblies, Protolabs taps into its global manufacturing network, ensuring the team accesses specialized capabilities without sacrificing speed. This comprehensive approach allows Harley-Davidson to implement holistic performance upgrades rather than isolated improvements.
Blueprint for Racing Innovation
The partnership demonstrates how digital manufacturing is transforming motorsports. By collapsing traditional development timelines, Protolabs enables race teams to implement continuous performance enhancements throughout the season. As the King of the Bagger series grows increasingly competitive, such rapid iteration capabilities are becoming essential for podium success. Harley-Davidson’s experience suggests similar digital manufacturing strategies could benefit other racing disciplines where incremental gains determine victory margins.
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