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Sagan ride to work-MOVIE

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Introduction- Influences and History

Michael SaganSenior Designer/Technology Principal

7 years with Trek Bicycle Advanced Concept Group

Designer for the past 6 Tour De France winning bicycles

Researching and implementing technology into Trek’s product development process

2005 Trek Madone 5.9 USPS Team Colors

Batavia, Illinois USA

Trek co-workers…

Lance Armstrong: 6 time Tour De France

ChampionRoland Green: 2 time World Champion

Not unlike a movie…

Hero VillansSidekicksLocationSpecial Effects

And of courseProps…

Concept to Victory (part 6)

Waterloo, Wisconsin USA

Introduction: Waterloo, Wisconsin

Trek in 1976…Mid 80’s…Trek today…

Introduction: a glimpse into Trek

Digital Trek

Trek today… Domestic Brands

Domestic Brands

Trek today… European Brands, aftermarket catalog and Nike

Trek Intro: other brands

Brands:

Klein

Lemond

Bontrager

Gary Fisher

Wrench Force

TCG

Technology of Trek: Materials

Technology: Carbon Fiber

OCLV: defined

Compared to the original Tour winner, an OCLV 110 carbon frame weighs 13% less -- yet it's just as strong. The difference? We optimized the amount of OCLV per square meter (110 grams) and reinforced it with high modulus carbon.

Using just 120 grams of carbon fiber per square meter translates into incredibly lightweight frames. At the same time, refinements in the OCLV process mean there's no compromise in strength or stiffness.

By sandwiching a honeycomb of Nomex® between layers of OCLV produces a structure so rigid, engineers can create just about any shape they want.

"OCLV is short for Optimized Compaction Low Void" "Basically, we compress carbon fiber and epoxy into a new composite that's stronger and lighter than carbon alone. Aerospace standards call for a 60/40 compaction ratio. The Trek OCLV process exceeds even that."

Jim ColegroveComposite Guru

Technology: Carbon Fiber

1m2= 120 g 1m2= 110 g 1m2= 55 g

GSM: defined

Technology: Madone Top Tube

Cross sections: Madone Top Tube

55 gsm OCLV120 gsm OCLV

Both sections:at same magnification

55 gsm material is used in construction of satellites

Technology: Future Materials

NanotubesControlling material at the molecular level.

• Developed by NEC and

IBM in 1991

• 50,000 times thinner than a human hair

• 100 times stronger than steel

• 6 times lighter than steel

French tennis racket manufacturer

Babolat incorporated small amounts of Nano Tube in their rackets in August of 2002.

Technology: a closer look at Trek

Trek: On OLN

Technology of Trek: Computers and Software

Technology- hardware and software

Partnerships:

Hardware

Software

CAID

CAD

Technology- 21st century tools

Tools:

Wacom Cintiq

Tablet PC

Design at Trek

Fast Trip to ACG

ACG:AdvancedConceptGroup

ID defined by the Industrial Designers Society of America

What is Industrial Design?

“…the professional service of creating and developing concepts and specifications that optimize the function, value and appearance of products and systems for the mutual benefit of both user and manufacturer…”

Technology- design process

Major Projects

1998Klein Carbon Mantra

1999Klein Quantum ProOCLV Road Redesign

2000OCLV USPS Team Time Trial

2001Klein Adept Full SuspensionOCLV TT Handlebars

2002USPS Team Time Trial

OCLV Carbon Fuel 2003OCLV WSD Road OCLV Madone Series

2004OCLV TT rev2 Bontrager OCLV TT Fork OCLV Madone Series

Design Process

Technology- design process

Project Team

Design Process

Technology- design process

Mission Goals

Design Process

Technology- design process

Timeline

Design Process

Technology- design process

BrandForm Language

Design Process

Technology- design process

ProductForm Language

Design Process

Technology- design process

DataCollectionAnd Research

Lance: on design

Technology: Lance on design

Design Process

Technology- design process

Add centerline drawing

Centerlines

Design Process

Technology- design process

Sketches

Design Process

Technology- design process

3D Models

Design Process

Technology- design process

Finite ElementAnalysisandWeight Predictions

Design Process

Technology- design process

AerodynamicPredictions

Design Process

Technology- design process

Digital Lance

Design Process

Technology- design process

Molding Parts

Design Process

Technology- design process

Frame Build

Design Process

Technology- design process

Road Test

Technology: Lance checks in

Lance:Feedback in 2000

Tour De France

Tour History

1903 the idea was to promote a magazine l'Auto

1919 l'Auto was printed on yellow paper and so the yellow jersey came to be

2003 100th anniversary of the Tour

4 people have won the tour 5 timesJacques Anquetil, Eddy Merckx, Bernard Hinault and Miguel Indurain

Lance Armstrong has won the tour 6 consecutive times

Greg Lemond was the first American to win (won 3 times)

Prologue - July 5: Paris, Eiffel Tower - ITT, 6.5 km Stage 1 - July 6: Saint-Denis/Montgeron - Meaux, 168 km

Stage 2 - July 7: La Fert sous Jouarre - Sedan, 204 km Stage 3 - July 8: Charleville M zi res - Saint Dizier, 167 km Stage 4 - July 9: Joinville - Saint-Dizier TTT, 68 km

Stage 5 - July 10: Troyes - Nevers, 196 km

Stage 6 - July 11: Nevers - Lyon, 225 km

Stage 7 - July 12: Lyon - Morzine, 226.5 km Stage 8 - July 13: Sallanches - L'Alpe d'Huez, 211 km

Stage 9 - July 14: Bourg d'Oisans - Gap, 184.5 km

Stage 10 - July 15: Gap - Marseille, 210 km Rest Day - July 16

Stage 11 - July 17: Narbonne - Toulouse, 160 km Stage 12 - July 18: Gaillac - Cap D couverte ITT, 48.5 km

Stage 13 - July 19: Toulouse - Plateau de Bonascre, 197.5 km

Stage 14 - July 20: Saint-Girons - Loudenvielle, 191.5 km

Stage 15 - July 21: Bagnres de Bigorre -LuzArdiden, 159.5 km

Rest Day - July 22

Stage 16 - July 23: Pau - Bayonne, 197.5 km

Stage 17 - July 24: Dax-Bordeaux, 178 km Stage 18 - July 25: Bordeaux - Saint Maixent l'Ecole, 200 km

Stage 19 - July 26: Pornic-Nantes ITT, 49 km

Stage 20 - July 27: Ville d'Avray-Paris-Champs Elyses, 160km

What is the Tour De France?

21 Stages

3 weeks long

2 rest days

Total:

3,395 kilometers or2110 miles

Location…

Jesery colors…

Polka Dot:Best Climber

Green:Best Sprinter

White:Best Young Rider

Yellow:Tour Leader

2004 US Postal Service Pro Cycling Team

Sidekicks…

26 members

9 tour riders

100 bikes

21st century bicycles

In the beginning…

40 lb bikes1 gear

2004 Bikes of the Tour

2004 Bikes of the Tour

Madone Series

The second worst thing that can happen…

Lance wins again.

What next?

New sponsors…

New designs…

7 Tour victories?

Not unlike a movie… there is an end

Q & A