design methodology - felt bicycles · jim felt dials in a prototype for wind tunnel testing ......
TRANSCRIPT
Felt athlete Charlie Sponsel rides the Virtue
1DESIGN METHODOLOGY
DESIGN METHODOLOGYThe introduction of a new Felt bicycle comes at the conclusion of a long,
thoughtful, and rigorous process. It may take years to complete the bike
development process from the first step of sketching the concept to the final
delivery of the bike at the Felt dealer. Felt could produce bikes faster and
cheaper, but there is good reason for this measured approach. Felt’s goal is to
produce the best bicycle possible, regardless of how long it takes.
Step one in this process is initiating dialog among Felt’s extended family of
experts. Sponsored teams and athletes, engineers, and product managers are all
encouraged to contribute ideas about what they want from a new bike. This open
discussion is critical and helps Felt determine core objectives. Once goals are
decided and conceptualized with sketches, the design process begins.
Jim Felt dials in a prototype for wind tunnel testing
Early sketches of the FAST suspension system
Each new frame first comes to life in the virtual world. Felt’s team of experienced
engineers create everything from the ground up, using an array of cutting-edge
computer software including Finite Element Analysis (FEA), Computer Aided
Design (CAD), and Computational Fluid Dynamics (CFD). All of this technology
allows the engineers to specify and experiment with every dimension of every
component on every new bike. This technology also enables designers to look
at the effect and fit of components such as wheels, brakes and derailleurs in 3D,
allowing them to understand how a complete bicycle is going to work as a whole.
Felt’s team then analyzes geometry and frame size dimensions, determining how
these complex relationships will affect handling and ride quality. Aerodynamics,
stiffness, and compliance are also considered and manipulated via adjustments
to tube shape and diameter. If the project is a full-suspension mountain bike,
linkage design and wheel path is assessed, refined, and tested.
2DESIGN METHODOLOGY
Felt engineers use state-of-the-art software for bike development.
FEA provides load analysis on a fork.
A 3D model shows internal cable routing & correct component fit.
It is in this phase that some of Felt’s most successful technologies such as the
Bayonet Steering System and Equilink suspension first came to life. For example,
when the engineers started working on the IA triathlon frame, they already knew
how to design the tubing intersections that yield a stiffer frame. Everything the
engineers discover–molding processes, tube shapes, or lay-ups–keeps building
on Felt’s end product.
When aerodynamics are a factor, like with the IA for example, Felt begins by
constructing 3D models in CAD where they can be analyzed and refined with the
CFD software. Next, complete physical models are made with Felt’s Fused
Deposition Modeling (FDM) machine. The FDM prints an actual 3D prototype
model and can be further reviewed, tested and modified in the wind tunnel. In the
past, tube sections were hand formed individually out of wood or bondo, resulting
in inconsistent and inaccurate shapes. Today, Felt creates a nylon prototype
in-house within a few days.
Both the CAD models and FDM prototype tubes are adjusted and refined dozens of
times before a complete FDM frame is created. When a full bike finally enters the
prototype phase, its design has already been subjected to countless hours of analysis
and tweaking. Only when engineers are completely satisfied with these outputs will
mold machining begin.
A 3D model of the Bayonet 4 fork system.
The Bayonet 4 fork system in use on the DA1
3DESIGN METHODOLOGY
Once the manufacturing molds are fashioned, carbon prototype frames are produced
and engineers begin experimenting with various lay-up configurations and blends of
carbon fiber. These subtle but critical adjustments allow for alterations in ride quality,
impact resistance, stiffness, compliance, and frame weight.
Felt takes it’s prototypes to the wind tunnel and continues to tweak the models until
it’s exactly where the engineering team wants it to be. Felt doesn’t simply use the
wind tunnel to ascertain how well a finished product works or as a marketing tool.
Instead, the wind tunnel is an integral part of Felt’s design arsenal and is used
throughout the design process.
Concurrently, these carbon prototype frames are brought to Felt’s internal testing lab
and subjected to rigorous static load and stiffness tests. These tests help determine
strength-to-weight ratios and gauge overall frame stiffness. Felt’s internal standards
are far higher than even the most stringent United States or European government
requirements. Felt also inspects prototype models to assess manufacturing
tolerances, surface finish quality, and precision alignment. Everything is checked,
tested, and checked again.An AR prototype setup in the windtunnel for testing.
An AR prototype set up for stiffness testing.
4DESIGN METHODOLOGY
Finally, and most importantly, these prototypes are ridden and not just by pro athletes.
Felt prides itself on being a company of cyclists and being their own harshest
critics. More complex endeavors such as full-suspension mountain bike frames or
aerodynamic time trial machines spend extensive time in the development phase
before the prototyping begins. Meanwhile, carbon fiber road bikes and hardtail
mountain bikes advance to the prototyping phase far faster, but then stay there for
extended time until material selection and lay-up schedules are perfectly dialed. In all
cases the goal remains the same: create the perfect blend of technological innovation
and material, achieving the unique lively feel of every Felt bicycle.
These coveted characteristics are not limited to Felt’s high-end bikes. Instead, there is
a constant stream of trickle-down technology. Of course there is an initial investment
in research and design, but that’s an investment Felt is always willing to make. A job
done right on the high-end bikes leads to same technology across all models.
The final stamp of approval doesn’t come from a computer program or a test
lab. That honor goes to the professional teams and athletes who use their Felt
bicycles to do their jobs. Only after these demanding testers sign-off is it time to
start production.
Felt Product Development Director Brian Wilson racing the Compulsion 10. The Hincapie Racing Team rolling out on Felt F Series road bikes.
The 2015 AR3 utilizes trickle down TeXtreme technology.
5DESIGN METHODOLOGY