DRR-022 - “THE UNCONV3NTIONAL”

We were immensely proud to work alongside the team at DNA Filters in the creation of a race-ready motorcycle with dimensions based on the Moto3 category of MotoGP equipped with an unconventional front system and manufactured only with materials and parts straight from the world championship.

Back in 2019, a new addition to the R&D team, Alexandros Maidis, a passionate engineer who is sharing the same passion about motorsports with Dino and Mario Nikolaidis, brought with him a portfolio provided with research on an alternative front system, based on the double wishbone suspension of Norman Hossack, optimized for lightweight motorcycles and a history of designing and manufacturing a couple of prototypes carrying a variation of such a set up. 

The last two years, owing to the pandemic’s lock down that has as a result the lack of business trips and exhibitions, lead the R&D team of DNA Filters, to thousands of hours of designing new products and innovative solutions for its production lines but most importantly gave them the opportunity to develop the new big thing… a lightweight race bike that will feature almost frictionless front and rear suspension! The target was clear. Near zero friction at all moving parts of the suspension, total weight less than a modern Moto3 bike but most importantly precisely engineered and manufactured.

And the R&D team set the main features for this project:

• Double wishbone front suspension

• No use of ball joints, only preloaded double row ball bearings

• Fully adjustable geometry

• Special intake system using SLS & FDM 3D printing technology

• Lightweight structure CNC Machined from billet aluminum

• Moto3 spec parts & dimensions

• As close as possible to 1:1 power to weight ratio

• Carbon fiber subframe & fairings

The Unconventional Approach

Already, modern telescopic forks feature good rigidity, acceptable static and dynamic friction. The target for the DRR-022 is almost zero static and dynamic friction. So it was clear from the beginning, the only way to go was by using nothing but ball and needle roller bearings in any joint for both front and rear suspension. No ball joints here! Another great aspect of this front suspension set up, is the fact that its kinematics are completely adjustable, meaning that the mechanic could change its characteristics in a couple of minutes, for instance, the percentage of diving during braking, just by inverting a couple of pivot points. Furthermore this front set up is designed in such a manner that provides a greater trail variation throughout thewheel travel aiming for the maximum stability during acceleration and high speeds without any compromise at changing direction.

Implementation

The fork is attached to the frame via two asymmetric CNC machined wishbones made from 7075 T651 aluminum. The bottom one is responsible for actuating the front shock absorber via a pull rod, giving a travel ratio of 2:1. Double row, preloaded ball bearings, are used for every single joint of this setup. From steering to suspension movement, the friction is minimized everywhere. The steering input from the rider to the fork is transferred via a scissor link, that is also using preloaded ball bearings. The goal for this setup was to eliminate every bit of play, from the assembly and at the same time, maintaining rider’s input to the fork and vice versa, giving as much feedback as possible. A unique shock absorber is developed by Hyperpro for this application, fully adjustable in rebound and high/low speed compression. Additionally linear or progressive springs can be used.

Lightweight

The chassis has a twin spar layout and is using the engine as a structural member. It consists of six CNC machined parts made out of 6082 T651 aluminum, welded together. With its 3mm wall thickness and its specially designed internal ribs achieves the preferable rigidity weighing only 3.6 kg. The rear subframe is made from carbon fiber. The front subframe is machined from 6082 T651 aluminum and apart from holding the steering assembly is also the top cover of the airbox. Despite the plethora of parts that constitute the front suspension, the R&D team managed to achieve a very low overall dry weight that does not exceed 75 kilos.

Breathing

One of the key components of this project is the ram air intake. The induction of the engine is designed in such a way that channels the air to a specially designed panel filter, directly from DNA’s racing division. The intake system consists of two basic components: The intake and the airbox. Both of them are 3D printed and thus there were no constraints about the design and manufacturing process. The intake is 3D printed from Nylon-CF, manufactured inhouse and it also works as the upper fairing mount which means that it has a lot of structural rigidity. The airbox is also 3D printed made from PA12 Nylon powder, with Laser Sintering technology. One of its key features is the fact that it has specially designed channels to guide the throttle cables that are traveling through it, without any opening that could allow debris to be “sucked” from the engine.

Acceleration

A brand new Yamaha YZ450F engine was chosen to power “The Unconv3ntional”. It is a race proven engine with a power output close to a modern day Moto3. The engine is precisely tuned in order to improve top end power output without compromising on reliability. A stand alone ECU took the place of the OEM one, in order to match the needs of the DNA forced intake system and the Akrapovic exhaust that is bespoke built for this bike.

Deceleration

The braking system of this lightweight racer is directly derived from the latest Moto3 bikes. Calipers and master cylinders came from the Accossato racing series. The front brake assembly uses a twin rotor layout with rotors of 220 mm in diameter-manufactured inhouse- and two twin piston radial CNC machined calipers. The radial master cylinder in the front is adjustable to 17/18/19mm of leverage.The rear radial caliper, like the front, is CNC machined twin piston and the rotor is 200mm in diameter.

Telemetry

In a project like this monitoring everything is mandatory. Especially during development. Thanks to the wiring loom custom-made by our partner Plex Tuning, every key aspect of this motorcycle will be monitored. Suspension position, steering position, accelerometers, GPS and brake pressure are few of the inputs going to the telemetry, plus full engine data. Everything is logged and displayed in the SDM-330 dashboard.

DRR-022 Specifications

· Engine: Single Cylinder Racing Engine

· Capacity: 449.7 CFM

· Engine Type: Water Cooled

· Bore/Stroke: 97mm/60.8mm

· Compression Ratio: 13.0:1

· Valve Train: 4 Overhead titanium valves

· Fuelling System: EFI, Keihin 47mm Throttle Body

· Transmission: 6 speed

· Clutch: Wet multi-plate clutch

· Final Drive: Chain

· Frame Type: Twin spar,Aluminum CNC machined

· Sub-Frame: Carbon Fiber

· Wheelbase: 1280 +/- 10mm

· Fuel Tank: Aluminum

· Fuel Capacity: 11.8L

· Weight: 75 kg dry weight

· Air Induction: 3D printed FDM NYLON-CF Ram-air & 3D printed SLS PA12 air box with DNA racing filter

· Exhaust: Akrapovic full titanium custom made for the DRR-022

· Front Suspension: Hyperpro 3D Shock race spec custom made for the DRR-022

· Rear Suspension: Hyperpro 3D Shock race spec custom made for the DRR-022

· Front Master Cylinder: Accossato Moto3 racing

· Rear Master Cylinder: Accossato Moto3 racing

· Front Brakes: 2 x 220mm disks, 2 piston Accossato Moto3 Radial billet calipers

· Rear Brake: 1 x 200mm disk, 2 piston Accossato Moto3 Radial billet calliper

Some info about the team

Firstly, Dino Nikolaidis, co-founder of DNA Filters, using his racing experience, engineering  and machining skills and his knowledge around materials like aluminum, titanium and stainless steel contributed decisively to fine tune the project setting the standards in some of the most critical parts and the overall manufacturing quality.

Next, Mario Nikolaidis, managing director of DNA Filters, through his valuable experience in managing and his modern communicative point of view, is the person who divided the duties and set the deadlines, coordinating the team, aiming for the best results. Besides, the right orchestration of a team for a project like this is equally important with the project itself.

Alexandros Maidis, the man behind this project, was responsible for intriguing the team with his vision in the first place, and remained open for new ideas, suggestions and advice concerning his design. Always there, contributing to anything he was asked and ready to advise and consult, kept the level high.

Conclusion

The team behind this operation is the whole company of DNA Filters. From the major  contributors of the R&D team to the procurement department. From the marketing division to the production line one thing is for sure, that without them, the end result wouldn’t be one that lives up to DNA’s standards.

Design & Engineering excellence!