How are bikes made? It's a question we've all asked, but how does a bike go from being an idea to being a design on a computer to then becoming a physical product? How does the process of making a bike work?
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00:00 - Bringing a bike to life and going from concept
00:02 to final delivery of that final bike
00:04 is an incredibly long and tricky process.
00:06 But how is it actually all done?
00:08 We went to Specialized in Morgan Hill and found out.
00:11 (upbeat music)
00:13 So I've just jumped inside and I'm joined by Cameron Piper.
00:23 Can you just introduce yourself and tell us a little bit
00:26 about what you do here at Specialized?
00:27 - Sure, so I joined Specialized almost eight years ago.
00:29 I was running our in-house wind tunnel
00:31 for about two and a half years,
00:33 working to develop our aerodynamic product
00:35 as I was working with a lot of our athletes.
00:36 And since then I moved over to the road product team,
00:39 specifically managing tarmac, Aethos, Shiv, and LA Sprint.
00:43 So all the performance road families we have
00:45 within the category of Specialized.
00:47 - So now when you're conceptualizing a bike,
00:51 you know, the very first steps of starting that project,
00:54 what does that look like and how do you go about it?
00:56 - Typically we start out with some different targets
00:58 based on the target rider that we have,
01:00 as well as experience that we're hoping to improve
01:02 for that rider.
01:04 And so with a project like LA Sprint,
01:05 it's a performance rider.
01:07 They want speed, they want a fast bike aerodynamically,
01:09 they want a bike that's handling really well
01:11 and how they expect it,
01:12 as well as a bike that rides really well
01:14 when it comes to a race experience or when they're training.
01:17 So we'll start off by setting those goals for the project
01:20 and spend a number of months really validating
01:23 and understanding how realistic those goals are
01:25 to fine tune the actual targets that we have
01:28 going forward into development.
01:29 - So then from that point, what's the next step?
01:32 Is it kind of a CAD process
01:34 or how do you then take it forwards from
01:36 once you've kind of analyzed
01:38 and set out those initial targets?
01:41 - So throughout that whole entire concept phase,
01:43 we're really taking some older projects
01:45 and learnings that we've had from those
01:47 and maybe cutting them up, testing the wind tunnel,
01:49 doing different things to really prototype
01:52 and understand the different performance
01:53 targets that we set for.
01:54 And throughout that whole process,
01:56 an engineer or designer is also working on the CAD
01:59 or the 3D for the new bike,
02:01 which allows us to then 3D print those models
02:04 or work on small manufacturing processes that we can
02:08 as we're moving towards a phase
02:09 where we're actually going to create the production CAD
02:12 or what we're actually moving to create tools with
02:14 and then test the overall frames structure.
02:17 When we're actually through part of the concept phase
02:20 and we have rough 3D planned out,
02:22 we're able to 3D print or kind of make a rapid prototype.
02:27 This one's machined out of ABS
02:29 to allow us to then bring it to the wind tunnel
02:31 and test some of the performance targets we have
02:33 specifically with aerodynamics.
02:34 Also by able to do this,
02:35 we're able to hold onto a frame physically,
02:38 which can tell you a lot about a project.
02:40 And then at the same time too,
02:42 with this one frame, if we said,
02:43 hey, we're not really where we want to be aerodynamically,
02:45 we can cut it up, we can 3D print other parts
02:47 and then place on this frame to say,
02:49 what can we tweak a little bit
02:52 to better meet those goals
02:54 and really take the next steps in the project.
02:56 - So with this one,
02:57 were there any specific learnings that you took
02:59 that then went into the final product?
03:00 - Definitely.
03:01 So this was a little bit further down the concept phase
03:03 where it was actually one of the second prints that we did.
03:06 And you can see here,
03:07 there was an adjustment of the seat stay height.
03:10 - Yes.
03:11 - And that was done a little bit more to say,
03:12 hey, can we get a little bit more out of the UCI box
03:14 that we have within this frame?
03:15 Can we make it a little bit faster aerodynamically
03:17 by moving the location of these?
03:19 At the same time too,
03:20 this project was running in parallel with Tarmac SL7.
03:23 So we're also learning things from each end of the project
03:26 that would kind of change the next steps for the project
03:29 as we moved along.
03:30 - Okay, so we have got here one of the first
03:33 fully built metal frames that came out of the Asian factory.
03:37 What role would have this played?
03:39 - So when it comes to the first frames
03:41 that we actually have welded together,
03:43 there's a lot of different things that we do.
03:44 We call them typically looking samples
03:46 because you learn a lot from that first process.
03:49 So whether it's weld alignment
03:51 or specific aspects of the frame with cable routing
03:54 or different things of actually building a bike with it,
03:56 it allows us to run through those different steps
03:58 and then also understand where we need to change
04:00 the manufacturing process for some of the tubes
04:03 or the actual welding alignment
04:05 or different aspects of that.
04:06 So like this frame, for example,
04:07 you can see this was done very early on in the process.
04:11 It was one of the larger frame sizes.
04:12 And there's a lot of aspects of the frame
04:14 that are not in the production version
04:16 because we learn things as we go.
04:18 - Yeah.
04:18 - So we'll be able to adjust
04:19 and make the product better as we go.
04:22 So like your different cable,
04:24 ICR grommets are no longer required
04:25 'cause we moved internal routing
04:26 in certain areas of the frame
04:28 or made this front trailer hanger completely removable.
04:31 - And then what's the next step after this?
04:34 Where do we go from here?
04:36 - So as we kind of tweak or ensure
04:39 that dimensionally this frame meets its requirements,
04:42 we're able to then bring it to the test lab
04:44 and say, does this frame meet the stiffness
04:47 and structural requirements that we have
04:49 for this frame to be the best frame it can be?
04:52 And that's a process where you're making a number of samples
04:55 and testing them to ensure that
04:57 based on the material thicknesses across the frame,
04:59 you're meeting those needs.
05:02 So there's quite a bit of work that's done after this.
05:03 And this is one of many samples
05:05 that allows us to kind of tweak and fine tune everything
05:08 to ensure that we're creating the right product.
05:10 - So we're onto testing now.
05:12 Talk to you about what you're doing
05:14 and how you're doing it
05:15 and what processes are involved in testing a frame.
05:18 - Right, so we spoke a little bit of FEA.
05:21 FEA helps us to understand those rider-based
05:24 stiffness metrics that we're aiming for
05:26 based on the tube shapes.
05:27 But now we get to the point where we can physically
05:29 test a frame in the test lab
05:31 to understand if we're meeting those stiffness targets.
05:33 And those stiffness targets are different targets
05:35 across the frame that we've developed
05:38 over a number of years, both in the lab,
05:40 but also with real world riders
05:42 to understand where the stiffness makes the most sense
05:44 for that experience that they're going for.
05:46 And then additionally, beyond that,
05:47 we also have a number of standards
05:49 that relate to the frame's overall strength
05:52 and how it will survive over a lifetime
05:54 of a rider's inputs,
05:56 whether it's those fatigue things
05:58 or the experiences that it might have out on the road
06:00 to ensure that it's safe to ride
06:02 and will last for that rider's entire lifetime, really.
06:06 - So that's lab testing.
06:08 What's the next step in that process?
06:10 - So typically after you get the first set of results,
06:12 both the stiffness results as well as the strength
06:15 and fatigue results, on a carbon frame,
06:17 you're adjusting the layup to either try to meet
06:21 one set of those targets or adjust something
06:23 across the frame in order to get to where you need to be.
06:26 And with the aluminum frame,
06:28 we're changing the thickness of the materials
06:31 across the frame in order to meet those targets.
06:33 So that's where we go back
06:34 and we basically manufacture other frames
06:38 to manipulate the frame in a way that allows us
06:40 to adjust based on the first set of results
06:42 that we'd received.
06:43 - So once you've got that final perfect recipe
06:46 of tube thickness and you're happy
06:48 with the geometry of the frame
06:49 and kind of everything's come together,
06:51 is it then just a case of pressing a big green button
06:54 and kind of putting the whole thing into production?
06:55 - I wish it was that easy.
06:56 So after we know we're meeting all the project's targets,
06:59 so we hit all of our aerodynamic goals,
07:01 we hit all the frame stiffness goals that we had
07:03 and the ride quality,
07:05 then we also need to make sure we're meeting
07:07 all those strength and fatigue goals that we had.
07:09 So we're meeting all the standards that Specialized has
07:11 to understand that this frame
07:12 is going to be the best frame out there.
07:15 And as we move into the next phase,
07:17 we're going back to the supplier
07:19 and we're saying, let's make a lot of these
07:22 and understand that as you ramp up
07:24 and you're creating more of these frames,
07:26 ensuring that all those welds are consistent,
07:27 ensuring that the frame dimensions are all consistent
07:30 across a larger scale of production.
07:32 And that's when you know you're really ready
07:34 to go into production
07:34 and ready to get to the next step of the project.
07:36 - What's that?
07:37 - That would be your full production approval.
07:39 - Yep.
07:39 - But there's a couple of things that were happening
07:42 along that time to kind of button things up
07:45 and some of that as well as ensuring
07:47 that we're field testing these frames,
07:49 making sure that not only in the lab
07:50 we're meeting all the targets,
07:51 we're also meeting them out on the road.
07:53 So we're involving a lot of people within the building
07:55 as well as some of our athletes
07:57 to ensure that this bike meets the needs,
07:58 not only on paper, but also out on the road,
08:00 which is extremely important.
08:01 - I mean, that's pretty far down in the process.
08:03 So how much change can the humans
08:06 out on the road actually have?
08:08 - A lot actually.
08:09 So it's usually we're field testing
08:12 when we have a frame that's safe to ride.
08:14 We know it's meeting all of our standards
08:15 when it comes to the strength and fatigue.
08:18 And at that point, if there's something that comes up
08:20 that maybe speaks differently to what we're seeing
08:24 in the lab, then we need to make sure
08:25 we have an action for that.
08:26 And that means we might have to take a change
08:28 and do something to ensure that riders
08:31 have the experience that they're expecting out on the road.
08:33 - Now, one of the most obvious things
08:35 that everyone sees when they look at the bike
08:36 is the colour of it.
08:38 And obviously you're going to end up
08:40 with a whole range of colours for all the different bikes
08:42 that you're going to be creating.
08:44 How does that work?
08:44 - Yeah, so usually early on in the process
08:46 when we have a 3D printed frame,
08:48 so something physical that our colours and graphics team
08:51 can actually take a look at,
08:52 that's when we bring them in.
08:53 So as a product manager, I'll help to set the,
08:56 really the stage for what this rider is
08:58 and what the experience is for that rider.
09:00 And with that, they'll take that information.
09:03 They build out colour palettes based on the year,
09:05 what's trending in the industry,
09:06 what's trending outside of the industry,
09:08 kind of what that next set of colours will be,
09:10 as well as specific graphics or paint techniques
09:14 we're developing in order to meet the overall needs
09:16 of what that experience might be.
09:18 So we have a team upstairs that's almost worldwide
09:20 in some ways, because they're really evaluating everything
09:22 across the globe to ensure that we're meeting
09:25 the needs of that rider.
09:26 - For the Alé Sprint, for example,
09:28 how many different options would have been created
09:30 to then whittle it down to that, you know,
09:32 the winning bunch?
09:33 - Yeah, we, at the start, kind of open it up
09:36 and let them decide on what's going to be used
09:39 with some graphics, what's going to be relatively clean
09:41 across the entire frame.
09:42 And with Alé Sprint, it's one of those families
09:45 that we try to keep a little bit more lively
09:47 because the frameset business is really important
09:49 for a lot of those riders who want to build it up
09:51 and really make it their own
09:52 based on their own style and look.
09:55 So there's a number of different colourways
09:56 that are maybe a little bit more fun
09:58 or use new techniques that we've developed
10:00 over a year or two to make this frame shine,
10:03 not only from the ways that it's been designed
10:05 by our engineers, but also for the rider
10:07 who's looking at it to show their expression.
10:09 - So there we have it.
10:13 Hopefully you found that really interesting and insightful.
10:16 If you've got any questions,
10:17 do drop them down in the comments below.
10:19 If you enjoyed the video, drop a like,
10:20 subscribe to the channel for more content,
10:21 and I'll see you again very soon.
10:23 (whooshing)
10:25 [BLANK_AUDIO]