Phase I: Product Development*
My senior product design capstone class asked us to develop a concept from deep ethnographic research to manufacturable prototype, and to mass-produce it. I collaborated with Brandon Skerda to form Revolve Bike Discs over the course of January to June 2013. In this first stage of product development, we met with cyclists throughout the San Francisco Bay Area, built and tested prototypes, and engineered the chain guard that could fit universally any bike while making a statement whimsical enough to attract interest. We then went on to develop a startup around the product.
You know when you’re biking and your jeans get caught and ripped in your chain? When you walk into a coffee shop with a grease mark on your right calf? I spent time with over twenty commuters in the Bay Area, and found many cyclists with their pant legs rolled up or tightened around their ankle by neon bands. Most adult bikes are not sold with chain guards attached, and most post-market chain guards are difficult to install or fundamentally disrupt the appearance of the bike.
Revolve Bike Discs is a better solution. They snap onto the sprocket, never forgotten and out of the way. Designs rotate with the pedal to make an attractive, whimsical pattern. The diameter of the disc is just large enough to create a wall between the chain and the leg without deterring jumping curbs.
The most difficult aspect of making Revolve Bike Discs was making the attachment universal. There are over 80 types of bolt patterns on bike sprockets, so bolting a prototype on bikes was not an option. Cyclists hated disrupting a perfect frame with superfluous attachments. We prototyped several options, including a coating for the chain and a large disc attached to the pedal.
Revolve Bike Discs is a better solution. They snap onto the sprocket, never forgotten and out of the way. Designs rotate with the pedal to make an attractive, whimsical pattern. The diameter of the disc is just large enough to create a wall between the chain and the leg without deterring jumping curbs.
The most difficult aspect of making Revolve Bike Discs was making the attachment universal. There are over 80 types of bolt patterns on bike sprockets, so bolting a prototype on bikes was not an option. Cyclists hated disrupting a perfect frame with superfluous attachments. We prototyped several options, including a coating for the chain and a large disc attached to the pedal.
Testing early prototypes
The most secure and lauded mechanism was direct attachment to the sprocket. Since we couldn’t use the bolts, we chose a strong adhesive from 3M and designed custom ball and socket pieces. The sockets can be attached at ideal spots on each unique sprocket, and the balls fit on the disc with a matching pattern. We designed the ball and sockets on Solidworks and 3d printed them in plastic.
The patent-pending attachment system
For prototyping purposes, we laser cut Revolve Bike Discs and attached cut vinyl to make designs. We talked to application engineers to narrow in on the best type of plastic for the weathered environment of bikers. Then, we received quotes from manufacturers on stamping, injection molding, and silk screening Revolve Bike Discs. Working with manufacturers helped us hone our Solidworks designs and silk screening processes to target our product toward mass-production.
*Click here to see the Business Development element of this project.
*Click here to see the Business Development element of this project.