At Formnext 2025, BLT unveiled a groundbreaking application from its Italian customer Extreme Manufacturing Engineering (EME), showcasing a hyper coaster boogie additively manufactured on the BLT-S800 system, which marks a significant leap forward in the amusement rides industry.
As a core component connecting the coaster train to the track, the boogie supports the carriage, guides its movement, and absorbs dynamic impacts from the track, ensuring stable and safe operation even under high-speed, complex maneuvers.
Produced from aluminum alloy AlSi10Mg, the topologically optimized boogie frame measures 570mm × 500mm × 400 mm and weighs just 17.2 kg. It replaces traditional multi-part welded assemblies, exemplifying how large-scale metal AM is transforming the amusement rides sector.
Highlights
Integrated Design: The AM-produced frame eliminates welds and mechanical junctions. This integrated approach not only enhances load distribution, stiffness, and material efficiency but also delivers greater structural integrity and superior reliability.
Lightweight Innovation: Weighing only 17.2 kg, the component is 60% lighter than its welded steel counterpart, providing a superior strength-to-weight ratio, enhanced dynamic response, and lower operational inertia. For amusement parks, it translates directly into significant energy savings of 20-30% annually and reduced wear on other operating components like wheels and bearings.
Ride-Tailored Durability: The geometry of the frame is optimized for high fatigue resistance and dynamic loading. This ensures an extended service life, enhanced safety, and a minimized risk of operational failure, instilling confidence in both park operators and thrill-seekers.
Streamlined Production & Reduced Costs: The rapid transition from 3D model to physical part significantly shortens component production time. Moreover, the integral design requires less maintenance and inspection, drastically lowering overall operational costs for amusement parks by minimizing downtime and extending the service life of the roller coaster.
BLT and EME entered into a strategic partnership at the Formnext 2023. The cooperation has been further deepened following the formal delivery of the BLT-S800 in June of this year.
The collaboration between BLT and EME demonstrates the potential of metal AM in producing large, high-performance industrial parts. It also showcases a clear path toward more efficient and cost-effective construction and operation of amusement rides.
The successful realization of this project was supported by Extreme Analyses Engineering, an engineering office that specializes in the design of additively manufactured components using dedicated fatigue-oriented software and methodologies.
