Kestrel KM40
The Winning Edge
When one looks at a bicycle frame do
mathematics necessarily come to mind? To the competitive
triathlete, a well designed bicycle frame can be the
winning edge. For the designers at IDE Inc.,
conceptualizing a bicycle frame meant perfecting a
challenging geometric design.
There is perfection in this
world: mathematical perfection. Complex mathematics,
specifically NURBS surfaces can be used to develop a
bicycle frame that is top of the line in every aspect
imaginable. Kestrel's KM40 Airfoil, designed for Kestrel
by IDE Inc., is an aerodynamic, lightweight, one-piece,
carbon fiber construction incorporating low wind
resistance airfoils throughout its form. Moreover,
advancements in computer aided design software,
Rhinoceros-NURBS modeling for Windows, provides a
creative platform for designers such as Doug Jones, IDE
Inc. CAD administrator and senior design engineer.
According to Jones, "With the degree of complex
surfacing involved, Rhino software was essential to the
development of such a unique product design."
Custom CAD
Using his own custom macro/workspace
for Rhino, Jones developed a complex network of blended
NURBS surfaces which were eventually imported into a
Parametric Technologies', Pro Engineer, parametric solids
modeler. The Rhino solids model was then used by IDE's
in-house model and prototype facility to manufacture a
full-scale, precision CNC, ABS plastic model. Once
Kestrel had assembled wheels and other components to the
CNC model, minor adjustments were made to the Rhino
model. The final model was imported to Pro Engineer and
then sent to Kestrel's production toolmaker for the
manufacturing of a steel tool.
Mastering The Details
For Kestrel-USA, manufacturers of the
KM40 Airfoil, performance combined with practical
production is the key. According to Kestrel R&D
Director Kevin Kenney, "This project was a major
step forward for Kestrel, and IDE should be credited with
masterfully creating the CAD model. With this new frame
we tried to define, in mathematical terms, the shape of
the frame. IDE had to incorporate these design elements
with literally hundreds of small details. We put a lot of
trust into IDE's design talent. One of the biggest
challenges was getting the look of the frame right while
maintaining a high degree of precision."
Form Equals Function
At Kestrel-USA, form is equally as
important as function. The employees at Kestrel not only
build top of the line bicycles, they ride them too. How
the bike looks aesthetically is as important as how the
bike performs. Not that either is less developed or
prioritized. Kestrel decisions are made by hands- on,
experienced riders, and their bikes look as high-tech as
they perform.
Using the same computer aided design technology as
automobile and aeronautical designers, IDE was able to
shorten Kestrel's product development cycle while
bringing a higher degree of precision to the design,
engineering, and manufacturing processes.
According to IDE founder and President Dave Moriconi,
"IDE's strength lies in our successful blending of
design sensibility, engineering know-how, and
manufacturing savvy. We get companies into production
with the least amount of headaches." The experience
of IDE's experts goes way beyond that of basic industrial
design. Over the years, IDE founded in 1985, has earned a
reputation for developing practical, unique, and exciting
designs. Taking cutting edge technology and making it a
consumer reality.
