Bicycle Composite Frame Development

Bicycle Composite Frame Development

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.

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.

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

Role

Product Designer

Year

Year

2019

2019

2019

Industry

Industry

Bicycle Manufacturing

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.

Initial phase: Research

Initial phase: Research

Initial phase: Research

The initial phase of this project began with in-depth research, uncovering the rich history of Robert Kubica’s impressive racing journey. Kubica’s career is a story of early talent and remarkable resilience. Starting in karting at age 10, he quickly rose through the ranks, achieving numerous titles in Poland and internationally. By 2001, he had advanced to Formula Renault and, by 2003, joined Formula 3, where he finished second in 2005.


Kubica’s breakthrough in Formula 1 came in 2006 with BMW Sauber, making history with his first Grand Prix win in Canada in 2008. That year, he finished 4th in the standings—the best result by any Polish driver in F1.


In 2011, a severe rally accident almost ended his career, but Kubica’s perseverance saw him return to racing in the World Rally Championship, where he claimed the WRC2 title in 2018. He then returned to Formula 1 with Williams in 2019, closing his F1 chapter in 2021. Kubica’s career remains a testament to his dedication and passion for the sport.

Phase II: Design

Phase II: Design

Phase II: Design

I designed 3 unique cycling graphics that perfectly reflect their owner's passion and professional history. It was an intense journey during which I jumped on his bike to immerse myself in his experiences and inspirations.

Virtual F1 track

I completed the F1 2019 game to fully understand the nature of racing and the world of the person I was creating for. My virtual pit stop allowed me to better understand their emotions and needs.

Designing with empathy:

I apply the same approach to every project. I put myself in the client's shoes to understand their needs and how they see the world. That allows me to create designs that are aesthetically pleasing, evocative, and carry a unique story.

Final step

After selecting the most suitable graphic concept, I proceed to the 3D design stage. It is crucial to thoroughly check how a bicycle's colours, finishes, and various options look. For this purpose, I most often use KeyShot or Blender software. These tools allow me to create precise documentation and decal shapes, which I then pass on to production.

Here is a detailed description of the process:

  • 3D Modeling: Based on the selected graphic concept, I created a three-dimensional bicycle model. This model is accurate in terms of geometry and proportions, allowing for a realistic design presentation.

  • Texturing: I apply textures to the 3D model, replicating the chosen colours and materials. I can test different colour variations, finishes (e.g., matte or glossy), and types of decals (e.g., metallic, chrome).

  • Lighting and Rendering: I use realistic lighting and rendering techniques to obtain high-quality images. That makes the design look like an actual photo of the bicycle.

  • Documentation: I create precise technical documentation that includes detailed information on decals' placement, shapes, and sizes. This documentation is essential for the company producing the decals.

After completing the frame project, I felt a certain sense of unfulfilled need. Although the design was refined and satisfying, I needed something to create a cohesive and polished concept. That's when I decided to design clothing that would perfectly complement the frame, creating a harmonious whole.

My intentions were based on several pillars:

  • Colour consistency: The clothing would draw inspiration from the colour palette of the frame, using the same shades or subtle variations. That would create a cohesive visual composition between the project's two parts.

  • Stylistic complementarity: The clothing style should correspond to the frame's character. For example, if the frame exudes elegance and minimalism, the clothing should follow the same aesthetic.

  • Enrichment of experience: The combination of frame and clothing would create an aesthetic effect and enrich the user experience. The clothing would become an integral part of the whole, complementing and enhancing its perception.

The proposal to design clothing is more than just a matter of aesthetics. It is a natural evolution of the project, expressing the desire to create something more than just a functional object. It is a desire to create a cohesive story in which the frame and the clothing become inseparable elements, forming a harmonious whole.

Phase IV: Summary

Phase IV: Summary

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 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 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.

Maja Włoszczowska
Maja Włoszczowska
Maja Włoszczowska

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

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

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."

"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."

"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.

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.

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.