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Engineering · Product development · 2016 Madone2016 model

Developing the Madone, then publishing the engineering.

My Madone work included defining project specifications and goals, leading a development team and managing a cross-functional team to publish the research. I am a co-author of the paper describing the 2016 platform.

The 2016 Madone platform.Product photograph · Trek Bicycle · rights to confirm
Stiffness

One stiffness number did not describe the whole response.

What matched

Four Émonda test frames had the same conventional bottom-bracket stiffness value.

What differed

The cornering model predicted different lateral displacement.

Figure 16: predicted lateral displacement of the four Émonda test frames. Predicted behavior, not a measured before/after weight or speed improvement.Trek Madone white paper (2015), p. 18 · original labels and units preserved
Measurement and model

Compare the prediction with the measurement.

Figure 17 compares measured and simulated down-tube strain during cornering. The paper reports 3% error for that example.

3%Reported error, measured vs. simulated strain · that example only
Figure 17: measured versus simulated strain at the middle non-drive-side down tube, during cornering.Trek Madone white paper (2015) · original labels and units preserved
Structure

Tube-in-tube construction

The arrangement separated the outer aerodynamic form from an inner member designed for compliance. Trek reported 57.5% greater vertical compliance than the nearest tested competitor, not 57.5% greater comfort.

57.5% greater vertical compliancevs. nearest tested competitorNot a comfort figure
Section view of the tube-in-tube arrangement.Trek Madone white paper (2015) · original labels preserved
Validation

Rider testing through development

  1. January 2014Three laminates evaluated in Mallorca.
  2. March 2014Revised prototypes and laminates tested near Livorno.
  3. December 2014Production-bike evaluation with three laminates.
  4. January 2015Final ride test.

Dates and stages from the white paper, p. 23. Team sessions.

The publicationThe engineering record

The published development record connects structural analysis, physical evidence and rider evaluation. These are team results. My co-authors are Brad Addink, Paul Harder, Jay Maas and Mio Suzuki.

Read the Madone white paper
Reggie Lund · Composites × Manufacturing

Bring the drawing. Bring the part. Bring the problem.