Harley-Davidson Factory Racing: Innovating at Record Speeds

Challenge

The production Harley-Davidson Road Glide motorcycle weighs up to 960 lbs. The Harley-Davidson Factory Racing (HDFR) team identifies ways to reduce weight, increase speed, and decrease the lean angle of the large bike during turns. All of this is complex due to the bike’s touring body design, especially when compared to Superbikes built for racing at breakneck speeds.

Solution

HDFR engineers constantly iterate designs. Their year-round need for quick-turn parts across a variety of manufacturing processes brought them to Protolabs in search of a digital manufacturing partner that can provide both prototype and race-ready parts. The partnership between Protolabs and HDFR has grown significantly since the King of the Baggers began in 2021.

Outcome

A Partnership Built for the Podium

HDFR has participated in the King of the Baggers series since its inception in 2021. In the beginning, the team was largely comprised of Harley-Davidson engineers working on the bikes in their free time. As the popularity of the race series grew, HDFR expanded to a full team of dedicated engineers, data analysts, and mechanics who work year-round to ensure Wyman and Rispoli are set up for success on race day.

Collecting first-hand feedback from the racers as they return from the track, and combining that with quantitative data analysing performance in every straightaway and turn fuels the bike’s evolution. HDFR engineers quickly iterate using Protolabs to manufacture quick-turn, high quality parts. Speeding iteration of injection-moulded, CNC-machined, 3D-printed, and sheet metal fabricated parts, the team has turned to both our factory-based services and Protolabs Network.   

3D-Printed Exhaust Translates to Tight Turns on the Track

Tight turns on the track are pivotal to HDFR’s success. Just one-half degree of extra lean angle during turns can reduce track time by about 1/10 of a second. With some racetracks sporting as many as 14 turns in a single lap, the benefits of increased lean angle are clear.

To that end, HDFR engineers constantly evaluate how they can modify parts on the bike to add extra lean angle, which can help maintain performance and comfort for the rider. The exhaust components on the right side of the motorcycle offered the best potential for improving lean angle, so the team turned to the design freedom of metal 3D printing at Protolabs to see what is possible.

The result was an organically designed exhaust that tucks in closer to the bike, ultimately allowing Wyman and Rispoli to ride closer to the ground on right-hand turns.

The DMLS-printed exhaust utilized titanium for a lightweight, organic design.

Tech Sheet: 3D-Printed Exhaust

Tighter turns translates to faster lap times on the track. Learn how 3D printing allowed for an organic exhaust design maximizing lean angle. 

View Tech Sheet

Quick-turn Machining for Post-Crash Competing

King of the Baggers riders race rain or shine. As you might expect, bad weather creates several on-track challenges. With riders handling the 280 kg (680 lb.) bike at high speeds in tight turns, hydroplaning and crashes are common. Finishing the race in even the worst conditions is paramount for the season-long points race, as failing to cross the finish line—even in last place—results in a steep slide down the leader board.

When a bike does go down, protecting critical parts from damage allows riders to continue competing. The shift assembly tops that list as it is especially susceptible to damage due to its position on the bike’s left side.

With a rainy forecast for the final race of the season and a top spot in the standings on the line, HDFR engineers designed a shift skid that Protolabs machined and delivered in two days. The part built to protect the shift assembly is intended to take the brunt of any damage on the left side. In the end, the part went on to play a critical role, not only in the final race but also moving forward, allowing riders to continue competing for precious points throughout the season.

Mandatory tight tolerances were achieved with 3+2 CNC machining.