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Bicycle Composite Frame Development

Discover the journey behind creating an Olympic-level bicycle. The model utilizes the company's carbon factory's potential and strengthens Polish know-how on a global industry stage. The assumption was to create a product without compromises, perfect in every way, and dedicated to racing.

Role

Product Designer

Year

2019

Industry

Bicycle Manufacturing

Client

www.kross.eu

Main Challenges

Develop a continuous evolution of the previous Kross Level model, creating guidelines for design development for the Kross brand.
Develop high-quality composite frame for Olimpic Games in Tokyo meeting weigh no more than 800 grams of final product.
Working on early COVID-19 pandemic realities and high market uncertainty.

Research:

My objective was to redesign the Kross Level carbon frame to not only meet but exceed customer expectations, pushing the boundaries of performance and reinforcing its position as Poland’s market leader. This ambitious project required a multi-phase approach that integrated comprehensive research, competitive analysis, and a thorough exploration of Kross’s product history. The goal was to create a new frame that embodied the essence of the Kross brand while integrating the latest innovations in cycling technology.

I began with an in-depth assessment of Kross’s existing product portfolio, focusing on how well the brand strategy aligned with customer feedback. This analysis covered both the technical specifications of the products and the perceptions held by customers. By doing so, I was able to pinpoint the core attributes that resonated most with Kross Level customers: superior quality and a rich brand heritage.

The insights from this assessment highlighted the critical importance of staying true to Kross’s foundational values while modernizing the Level line. It became clear that the redesign needed to preserve the brand’s established identity, even as it evolved to meet the changing expectations of contemporary riders.

I conducted a detailed study of the Kross Level series’ evolution from 2011 to 2020. This historical analysis revealed the features and design elements that consistently appealed to customers, shedding light on what made the brand’s appeal enduring over the years.

To create a coherent product hierarchy within the Kross brand—particularly concerning the XC and XCFS lines in the 2019 collection—I worked on defining the unique positioning of each Kross Level model. The aim was to ensure that every model in the lineup offered distinct features tailored to the specific needs of different rider profiles. This strategy clarified the Kross Level’s role within the overall brand structure, aligning each model with targeted customer expectations and strengthening the brand’s identity and market presence.

Seeking to enrich the redesign with practical insights, I conducted interviews with Kross brand ambassadors and professional MTB riders Jolanda Neff and Maja Włoszczowska. Their firsthand experiences and feedback on Kross bikes were invaluable, offering critical guidance that informed key aspects of the design process.

Jolanda Neff

Swiss cyclist, 2020 Olympic gold medalist in cross-country cycling

World mountain biking champion Jolanda Neff, during an interview, paid special attention to the importance of the bike's geometry. Manoeuvrability and instant response to steering wheel movement allow precise cornering and full control over the bike, even in difficult conditions.

The champion suggests improving the head angle of the frame - this will significantly improve the smoothness of the ride, providing stability and comfort when cornering with the new Level.

Maja Włoszczowska

Polish cyclist, 2008 and 2016 Olympic silver medalist in cross-country cycling

The redesign of the Level CF carbon frame was a pivotal step in transferring its production to Kross’s own factory in Poland. This move streamlined manufacturing and enhanced control over quality and innovation, reinforcing Kross’s commitment to high technological standards in domestic carbon frame production.

By emphasizing unique aesthetic elements inherent to Kross, the new design maintains strong brand recognition. Key characteristic features were preserved and updated, blending heritage with modern design to solidify Kross’s image as a maker of high-class carbon bicycles for both loyal enthusiasts and new customers.

Design:

The project of designing the Kross Level frame series included carbon fibre (CF) and aluminium models. As the premium option, the CF model demanded a cutting-edge approach to achieve a lightweight and visually stunning frame.

Task

My primary responsibility within this project involved defining the final shape of both frames. That required a meticulous analysis of the complete 3D CAD model of the entire bike.

Action

During the R&D process, the development team identified "refinement" as our core objective. That encompassed functional aspects like ride quality and the bike's aesthetics. My goal was to build upon the success of the existing Kross Level by meticulously enhancing every detail.

Geometry: We developed a geometry defining the planned product and serving as the foundation and reference points for designing the shapes. We have started working on the project with the engineer based on the data we collected earlier.
Polygonal Modeling: I leverage polygonal modelling software that allows for incredibly fast iteration. While creating a solid model with perfectly smooth curvature across all surfaces can be time-consuming, often taking days or weeks, polygonal modelling offers a significant advantage. I can change the design in mere seconds, be it for engineering or aesthetic purposes. This agility proved invaluable – the model on the left, for instance, reached 80% completion within a day. While the final 20% refinement takes time, polygonal modelling significantly streamlines the earlier stages regardless of the software. This fluidity allows me to explore the design space thoroughly, making countless minor tweaks daily until the form reaches its optimal state. It's essentially digital clay modelling, offering the same design flexibility.

Task

My primary responsibility within this project involved defining the final shape of both frames. That required a meticulous analysis of the complete 3D CAD model of the entire bike.

Action

Geometry: We developed a geometry defining the planned product and serving as the foundation and reference points for designing the shapes. We have started working on the project with the engineer based on the data we collected earlier.
Polygonal Modeling: I leverage polygonal modelling software that allows for incredibly fast iteration. While creating a solid model with perfectly smooth curvature across all surfaces can be time-consuming, often taking days or weeks, polygonal modelling offers a significant advantage. I can change the design in mere seconds, be it for engineering or aesthetic purposes. This agility proved invaluable – the model on the left, for instance, reached 80% completion within a day. While the final 20% refinement takes time, polygonal modelling significantly streamlines the earlier stages regardless of the software. This fluidity allows me to explore the design space thoroughly, making countless minor tweaks daily until the form reaches its optimal state. It's essentially digital clay modelling, offering the same design flexibility.

Task

My primary responsibility within this project involved defining the final shape of both frames. That required a meticulous analysis of the complete 3D CAD model of the entire bike.

Action

Geometry: We developed a geometry defining the planned product and serving as the foundation and reference points for designing the shapes. We have started working on the project with the engineer based on the data we collected earlier.
Polygonal Modeling: I leverage polygonal modelling software that allows for incredibly fast iteration. While creating a solid model with perfectly smooth curvature across all surfaces can be time-consuming, often taking days or weeks, polygonal modelling offers a significant advantage. I can change the design in mere seconds, be it for engineering or aesthetic purposes. This agility proved invaluable – the model on the left, for instance, reached 80% completion within a day. While the final 20% refinement takes time, polygonal modelling significantly streamlines the earlier stages regardless of the software. This fluidity allows me to explore the design space thoroughly, making countless minor tweaks daily until the form reaches its optimal state. It's essentially digital clay modelling, offering the same design flexibility.

Blender 3D Polygonal Model

Solidworks Parasolid CAD Model

Blender 3D Polygonal Model

Solidworks Parasolid CAD Model

Blender 3D Polygonal Model

Solidworks Parasolid CAD Model

Polygonal modelling & FEA Utilising: I used Blender software to create 3D models, experimenting with various shapes and proportions. To optimise time and ensure structural integrity, we developed a solution: a script that could convert these Blender models seamlessly into the SolidWorks' parasolid shape. That enabled smooth integration with Finite Element Analysis (FEA) software, allowing us to meticulously assess the frame's strength at every design stage.
Prototyping: Our engineering team meticulously crafted complete 3D-printed prototypes and essential junctions in the design in carbon parts to thoroughly validate the design before production for in-depth analysis and testing. This commitment to R&D is evident in the custom tooling we created for each component — a significant investment even before finalising the design. Multiple iterations of the Level frame were built to ensure the next generation of this mountain bike achieved its full potential.

Results

TO DO

Results

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Results

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Phase IV: Summary

The Kross Level mountain bike is a testament to the brand's commitment to innovation and technological advancement. The development of the carbon fiber frame for this model represents a significant step forward for Polish cycling and lays the foundation for future advancements in composite materials.

The Kross Level line has already garnered critical acclaim, with the aluminum version receiving an average rating of 4.6/5.0. It has become a popular choice for both urban commuting and MTB riding.

The carbon fiber version of the Kross Level takes the bike to a whole new level, making it a top choice for professional racers. It has been prominently featured in various competitions, including the Tokyo Olympics.

Olympic Performance

Maja Włoszczowska, a renowned Polish cyclist, rode the Kross Level Carbon to victory at the Tokyo Olympics. The Olympic course was notoriously challenging, with steep, rocky descents that demanded exceptional skill and technique. Włoszczowska dedicated a significant amount of training to perfecting her downhill technique, including practising in Andorra.

The Kross Level line has already garnered critical acclaim, with the aluminum version receiving an average rating of 4.6/5.0. It has become a popular choice for both urban commuting and MTB riding.

Olympic Performance

The Kross Level line has already garnered critical acclaim, with the aluminum version receiving an average rating of 4.6/5.0. It has become a popular choice for both urban commuting and MTB riding.

Olympic Performance

Maja Włoszczowska

Polish cyclist, 2008 and 2016 Olympic silver medalist in cross-country cycling

"Downhill training is crucial," she emphasized. "In Leogang, for instance, I had a clear path on the final descent during the last lap and completed it in 1 minute and 13 seconds. However, when a slower rider was ahead of me earlier in the race, I took 1 minute and 30 seconds. Losing 17 seconds on a single descent is impossible to make up on the uphill sections. The difference is remarkable. And that's not to mention that a rider crashed in the same spot on the first lap, and I had no way to pass her, resulting in a total descent time of 2 minutes. 47 seconds slower on one descent! That highlights the significance of starting position and technique."

Włoszczowska opted for a hardtail bike, which features suspension only in the front fork, for the Olympics. She explained her decision: "It's lighter, shorter, and more agile. The course features numerous steep climbs where bike weight is a significant factor. Additionally, many tight corners require near-zero braking and subsequent acceleration. While a full-suspension bike would provide a more comfortable ride on descents, I can handle the Kross Level hardtail effectively enough to avoid losing ground to my competitors on full-suspension bikes."

The Kross Level Carbon stands out as a prime example of Polish cycling's technological prowess, showcasing the brand's ability to produce high-performance bikes that meet the demands of both professional racers and recreational riders.