The project to manufacture a mountain bike frame, led by a group of second-year students, benefited from a new 5-axis milling machine acquired through the ELF program. A truly authentic learning experience!
A machine serving a specific project
The high-performance 5-axis milling machine, acquired as part of the ELF program, found a direct educational application in the project to manufacture a mountain bike frame. The team of students, led by Clément Pavani, proposed this project to compete in a mountain bike enduro race in July 2026. This versatile discipline combines efficient climbs with fast descents. It is practiced on technical trails featuring natural obstacles such as roots, rocks, jumps, and steep slopes. It is therefore an intense and demanding sport for both the rider and the bike.
According to Laurent Laboureau, a professor at UGV, the machine “was used to efficiently produce mountain bike frame parts” and “avoided the need for complex rework on other machines.” The project also made it possible to test and validate, on the 5-axis milling machine, the digital workflow available on the Cluny campus and used in the industrial sector, with 3Dexperience for design and toolpath generation and NCSimul for machining simulation.
This application reflects the machine’s specifications. The DMG Mori DMU90P 5-axis milling machine replaces a machine from 1993. It is described as a rigid and precise machine, featuring high spindle torque and high thrust forces on the axes. “Its state-of-the-art, user-friendly CNC control system, which is compatible with PC simulators, makes it a valuable tool for student training,” explains Guillaume Fromentin, the ELF representative on campus.
A project praised by the Minister of Industry
“We had a group of extremely motivated young people who poured exceptional energy into their project. Thanks to that energy, they were able to bring the mentors, teachers, and technicians along on their journey. It was this momentum that made the project a success. Congratulations to this extraordinary team!” said Laurent Laboureau.
This appreciation is fully shared by the other faculty members. “An incredible group of students—bold, exceptionally dedicated, attentive, and responsive to all advice. They’ve done a tremendous job that fully deserves to be recognized. Bravo for all that energy! I was very proud to accompany them on this adventure—a truly authentic learning experience—alongside all my colleagues. Thank you to them for their trust and dedication. I wish them every success as they move forward on their journey,” says Agnès Bourg, professor of humanities and social sciences.
“The students were proactive right from the pre-design phase, conducting a very early search for partners. With the group so motivated, I couldn’t afford to leave them by the wayside, so I supported them in finding partners to supply the raw materials and fasteners, and in addressing some Computer-Aided Manufacturing (CAM) issues. Their commitment from start to finish allowed everyone involved to ride the wave of their unwavering motivation, despite all the challenges inherent in producing such intricate parts. “Congratulations to this team of students who stuck with it until the very end,” enthuses Benoit Madelaine, a design engineer on the UGV team at LaBoMaP.
The students presented their prototype to Sébastien Martin, Minister of Industry, at their Arts et Métiers booth Arts et Métiers the most recent Global Industrie event in Paris, and he praised their project in a social media post.
“The enduro mountain bike race has been canceled, but the entire team will present their work at theupcoming CIRP HPC conference from June 17 to 19, 2026, on the Cluny campus,” concludes Clément Pavani.
A New 5-Axis Milling Machine for Training and Research
The DMG Mori F5AHP high-performance 5-axis milling machine (model DMU90P) is designed with Industry 4.0 in mind thanks to several integrated features:
- a tool wear and collision monitoring system developed with the support of Digitalway,
- a monitoring system from Five CORTX (sponsor),
- a Siemens solution for monitoring energy consumption,
- a palletizing system provided by EROWA (a corporate sponsor),
- tool holders supplied by KENNAMETAL.
A future project involving automated loading using AMRs and cobots is also being considered as part of the ELF ROAM project.
Funding for this new machine comes from several projects and initiatives: RECLASSIF for the study and optimization of energy consumption in machining; ICARTS MODUS for the characterization of kinematic and thermal fields during the machining of refractory superalloys; the ELF program through the Arts & Métiers Foundation for education and training in 5-axis milling; a digital twin project for milling; and the Delage project.
