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.

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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.

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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.

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