…and this is how the idea of DRR-022 was born. The DNA Real Racer. The creation of a race-ready motorcycle with dimensions based on the Moto3 category of Moto GP 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
This project was set to be an extremely demanding engineering task putting human and machines to their limits with the highest quality and precision standards. As DNA filters always aims in all of its engineering fields.
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.
Engine: Single Cylinder Racing Engine
Capacity: 449.7 CC
Engine Type: Water Cooled
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: 75kg 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
Considering all the things above we believe that the end result is nothing short of amazing. Today, here in Milano, at Eicma 2022, we proudly present to you one of the most challenging projects that we have put our hands on, showing on a global level, what our company is capable of.
Firstly, Dino Nikolaidis, co-founder of DNA Filters, using his racing experience, engineering and machining skills and his knowledge around materials like aluminium, 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 to 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 a first place, remained open for new ideas, suggestions and advices concerning his design. Always there, contributing to anything he was asked and ready to advice and consult, kept the level high.
The team behind this operation is the whole company of DNA Filters. From the major contributors of 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!
We hope that you will enjoy The Unconv3ntional.
Standard fit 165 gsm 85% Cotton – 15% Viscose perfect for wearing under a motorcycle jacket.
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