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