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