mountain bike design

We are experts in mountain bike design, both fully’s, ebikes and hardtails. From concept design, geometry, kinematics simulations and full CAD engineering, we can help you up to production of carbon moulds.

crazy about mountain bikes

We are a bit crazy about mountain bikes. No matter whether they are fully’s or hardtails, light ebikes, gearbox bikes or derailleur bikes.

Every year our team is out riding for a week in Croatia or Slovenia, for fun. But during the season we are on our bikes very regularly, both for fun and for testing the bikes we develop.

strategy

We start off with research into the use of the bike, observations of riders, riding conditions, technological limits, innovation opportunities, company identity and many other factors that are important for a successful design project.

We also develop detailed idea’s about geometry, kinematics, drivetrain, components and sizing strategy.

The research leads to a strategy document with a clear innovation focus, potential risks and visual identity of the new mountain bike and serves as a strategic guide throughout the total project.

kinematics and geometry

During the design of new bicycles we use simulation software to develop solutions for bike suspension, kinematics and geometry.

We do not only simulate, but riding many bikes, testing with mules and making small iterations helps us to design a geometry and kinematics that fits the bike we are developing.

concept development

Through rapid cycles of sketching our senior designers investigate many potential rough bike design idea’s and test this with early mockups.

We identify and choose the best bike design direction from all the possible ideas and make choices based on testing, experience and strategy.

During the concept design phase, we have a ‘look-in-the-kitchen’ session with your team. We present directions in sketch-form, functional and technical solutions, manufacturability solutions and mockups.

Together with your team we discuss focus, risk, level of ambition and push the design direction further into a concept that we will develop further.

engineering

The first important milestone during the design of new bikes is to bring the concept to a first fully functional prototype. This first prototype we call the P1.

To do so, we use powerful 3D CAD software to develop the bike. We design all frame parts, pivots, bearings, rockers and integrate standard components. In parallel we select materials, production methods, treatments, possible coatings and colors.

To achieve maximum performance at minimum weight we use 3D CAD simulations and tests with prototypes.

In addition to a set of 3D CAD files, a bill of materials and a first brief 2D package of drawings are made during the transition to production of the first P1 prototype.

prototyping

Both during the concept and engineering phases we build prototypes. Early prototypes are mostly more like mockups and are often 3D printed. We use them mainly for testing shapes, ergonomics and engineering solutions.

At the end of the engineering stage we build the first P1 full functional prototype. These prototypes are high quality, often CNC milled, coated, with graphics and fully functional.

The P1 prototype will be tested, both on functional, ergonomic and performance aspects. We document all the learnings and develop improvements in stability, cost, weight and performance. Mostly this leads to an updated prototype P2.

After one or sometimes more cycles of improvements the product is ready for manufacturing on a larger scale.

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