Kestrel Talon
Success Begets Success
 In early 1999, specialty bicycle manufacturer Kestrel-USA came to IDE for help designing a new bicycle. Six months later the KM40 Airfoil was introduced. With its one-piece, air foiled, carbon fiber construction targeted to tri-athlete time-trial riders, the KM40 garnered multiple design industry awards during 1999 and 2000.

Realizing that the success of the KM40 program was due in large part to IDE's unique combination of design and engineering skills, their understanding of complex sculptural forms and precise 3D CAD development which translates directly into highly accurate compression mold tooling, Kestrel again retained IDE to take on a new and unique challenge in bicycle frame design - to develop five new modular carbon composite aerodynamic road frames within a development cycle previously unheard of.

Manufacturing Efficiency, Fast Development, Striking Visual Effect

Kestrel's mission was to develop a modular carbon frame that would be offered in five different sizes. The modular construction would have common chain and seat stays which, through a common fluid seam, would mate to five different triangles, or main frame sections. This strategy allowed the use of smaller tools that are easier to heat and cool, providing manufacturing efficiency, a faster development cycle due to part commonality, and a distinct aesthetic created by the mating details of the chain and seat stays with the main frame sections.

Kestrel began initial design concepts using the industrial designer who had designed several of Kestrel's earlier bike frames. The design would be a reincarnation of the Kestrel 4000, but with enhanced aerodynamics. Once the look of the frame was established, Kestrel's designer made a hand-crafted model of one of the five frame sizes. With the selected profile and the hand crafted model in hand, IDE began the refinement and detail design.

Five New Frames in a Fraction of the Time

IDE's first technical challenges was figure out a way to develop the 3D NURBS CAD models so they could be modified to create the four additional frame sizes without starting from scratch for each size. One of the mid-size frames, the Model 570 (57 cm) would be developed first. This was followed, in order, by the Model 520 (52cm), Model 550 (55 cm), Model 480 (48 cm), and finally the Model 600 (60 cm). IDE began the development of the 570 in April 2000.

IDE began by developing a modeling strategy to efficiently handle the development of the five different frame sizes. The fixed mounting points for each frame size were laid out in ProEngineer with a "relations" script for all five frames. We determined that each frame would have its own developed triangle that would mount to a common chain stay and to either one of two seat stays. This meant we had to develop the detail design for five triangles, two seat stays, and one chain stay. The "relations" data were then imported into Rhino 3D for the basis of the NURBS development of each bike.

The two seat stays and the chain stay, which are common elements, were developed first. The mating seat tubes were unique to each frame size. The airfoil sections of the triangles were designed "floating" without seams or joints. The tube element of each triangle had a different angular relationship and position; thus a master file was created in Rhino with the five major tube elements.

The main tube was designed with a high NURBS UV mesh density, making it possible to remove and add sections of the mesh for size changes. The mesh had to be dense enough to ensure the bond joint section remained intact regardless of the tube length. Once all components were positioned properly, blended joints were placed between the tube sections and the secondary features were added for cable ports, derailleur, and water bottle mounting.

Using 3D CAD modeling as opposed to hand-made wooden molds and plastic prototypes, IDE detailed five different frames in a fraction of the time traditionally required.

Success Redux

Kestrel introduced the first two production-tooled models by September of 2000. IDE were able to complete the development of all five frames by November, 2000, for a remarkably short development cycle of only eight months for five designs.

The cost savings resulting from the Talon's three-piece frame has made it possible for Kestrel to sell the new models at a starting price of $1,300, one-third the price of their other models. Talon has since become Kestrel's best selling model and has added to Kestrel's reputation and pre-eminent status in the biking world.

To keep the overall look of the bike cohesive, IDE also developed the product branding for the Talon. Just as with the frame design, the graphics updated the design language of the original Kestrel 4000, adding unique Talon imagery. The bold color palette of the 4000 was integrated into the new graphics and the juxtaposition of the various colors was done in such a way that common decals could be used effectively on all frame colors.

Continuing Support

IDE's involvement with the Kestrel Talon didn't end with the initial success of the bicycle. Since the introduction of the Talon, IDE has continued to support the product. We have twice updated the product branding, graphics and color schemes to keep the designs fresh and to extend the market appeal of the bike.