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Developing the ultimate road racing bicycle frame Adam Wais | Founder & CEO | Rolo Bikes Altair ATC | Paris | September 30 | 2015

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BACKGROUND OBJECTIVES ACTION RESULT

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BACKGROUND

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In 2010 - as customers - we asked ourselves what the best road bicycle in the world was. What did we think determined the ”best” bicycle? The hierarchy of importance in road bicycles: 1. Fit 2. Handling 3. Physical characteristics THE ‘BEST’ BICYCLE?

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The industry has moved from metal tubed frames to carbon composites. Some custom metal tube builders switched to carbon tubing while large manufacturers mold frame sections. WHAT WHY HOW

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OBJECTIVES

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Establish the engineering targets • EN 14781 • Weight, stiffness, comfort: the Tour Magazin test protocol How do we achieve those targets? Is it even possible? Do we have to make and break dozens of frames? There has to be a better way. PERFORMANCE

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Weight: under 750g PERFORMANCE OBJECTIVES Head tube stiffness: over 96 Nm/deg Bottom bracket stiffness: over 65 N/mm Comfort: under 200 N/mm

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ACTION

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How do we do the engineering and who can help us? Replicated the EN test jigs as well as the Tour Magazin test in Hyperworks using Optistruct. Manufactured test frames which were then tested physically to correlate results and refine the virtual jigs. WHAT DID WE DO?

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OPTIMAL STRUCTURE

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1. Front impact 2. Falling frame impact 3. Fatigue test - frontal forces 4. Fatigue test - pedalling forces ABUSE LOAD CASES

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1. Head tube stiffness 2. Bottom bracket stiffness 3. Comfort test TOUR MAGAZIN TESTS

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FRONT IMPACT TEST

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FRONT IMPACT TEST

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BOTTOM BRACKET STIFFNESS

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HEAD TUBE STIFFNESS

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HEAD TUBE STIFFNESS

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The virtual jigs now permit us to tailor the carbon lay-up to the customer’s weight, stiffness and comfort preferences. We are the only manufacturer in the world who can do so. VIRTUAL JIGS

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RESULT

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THE BICYCLE Weight: under 700g (target under 750g) Head tube stiffness: over 97 Nm/deg (target 96 Nm/deg) Bottom bracket stiffness: over 115 N/mm (target 65 N/mm) Comfort: under 160 N/mm (target 200N/mm)

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Depending on the lay-up, our frames are about 50% stiffer than the competition in the bottom bracket, more than 15% stiffer in the head tube and roughly 66% more comfortable. Our development time is much shorter and roughly 33% of the cost or less than that of our competitors. THE TOOLS

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WHAT NOW FOR COMPOSITES? Composites design and engineering tools are ready. Optimization at all scales has never been easier. Now manufacturing needs to catch up.

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Adam Wais adam.wais@rolobikes.com www.rolobikes.com Mob: +46 736 333 699