Competition cycling

 KWSP were approached to design an aerodynamic solution for the packaging and integration of electric gear change units.


The Challenge

  • A rapid prototyping method was required to enable multiple design iterations.
  • Component required the strength to withstand loads during windtunnel testing.

The Requirements

  • Design needed to be aerodynamic.
  • Electronics unit needed to be integrated but accessible.
  • End product was to be manufactured in carbon fibre.

The Approach

  • The design was modelled by KWSP’s engineers and tested through FEA and CFD.
  • A prototype component was 3D printed in ABS to be validate the design with the client team.
  • A further prototype was then manufactured in Ultem to provide the strength required for wind-tunnel testing.

The Results

  • Rapid sign-off of proof-of-concept.
  • Rapid movement from design validation to wind-tunnel testing.
  • Removal of tooling costs.