# Presentation: 469191

## Start

## Sagan ride to work-MOVIE

- SEE VIDEO IN
- WINDOW AT LEFT

## Sagan Intro

**Introduction- Influences and History**

**Michael Sagan**
- Senior Designer/Technology Principal

- 7 years with Trek Bicycle Advanced Concept Group
- Designer for the past 6 Tour De France winning bicycles
- Researching and implementing technology into Trek’s product  development process

**2005 Trek Madone 5.9 USPS Team Colors**

## Batavia IL

**Batavia, Illinois USA**

## Co-workers

**Trek co-workers...**

**Lance Armstrong:**** **** 6 time Tour De France**
**Champion**

**Roland **
**Green:**** **
**2  time World Champion**

## Concept to Victory

- Hero
- Villans
- Sidekicks
- Location
- Special Effects
- And of course
- Props...

**Concept to Victory**

**(part 6)**

## Design Process

**Waterloo, Wisconsin USA**

## Trek History

- Trek in 1976...

- Mid 80’s...

- Trek today...

##  Digital Trek Movie-MOVIE

**Introduction: a glimpse into Trek**

**Digital Trek**

## Domestic Brands

**Domestic Brands**

## Add European Brands and aftermarket catalog slide

**Add European Brands and aftermarket catalog slide**

## Trek Brands-MOVIE

**Brands:**
**Klein**
**Lemond**
**Bontrager**
**Gary Fisher**
**Wrench Force**
**TCG**

## Design Process

**Technology of Trek: Materials**

## OCLV defined

**OCLV****: ****defined**

- Compared to the original Tour winner, an OCLV 110 carbon frame weighs 13% less -- yet it's just as strong. The difference? We optimized the amount of OCLV per square meter (110 grams) and reinforced it with high modulus carbon.** **

- Using just 120 grams of carbon fiber per square meter translates into incredibly lightweight frames. At the same time, refinements in the OCLV process mean there's no compromise in strength or stiffness.

- By sandwiching a honeycomb of Nomex® between layers of OCLV produces a structure so rigid, engineers can create just about any shape they want.

**"OCLV is short for Optimized Compaction Low Void"**** "Basically, we compress carbon fiber and epoxy into a new composite that's stronger and lighter than carbon alone. Aerospace standards call for a 60/40 compaction ratio. The Trek OCLV process exceeds even that."**

**Jim Colegrove****Composite Guru**

## GSM defined

**GSM****: ****defined**

## 55 vs 120

**Cross sections:**
- Madone Top Tube

*55 gsm OCLV*

*120 gsm OCLV*

**Both sections:**
- at same
- magnification

**55 gsm** material
- is used in
- construction of
- satellites

## Future Materials

**Nanotubes**

- Controlling material at the molecular level.
-  Developed by NEC and IBM in 1991
-  50,000 times thinner than a human hair
-  100 times stronger than steel
-  6 times lighter than steel

- French tennis racket manufacturer Babolat incorporated small amounts of Nano Tube in their rackets in August of 2002.

## Trek on The Lance Chronicles-MOVIE

**Trek: **
- On OLN

## Design Process

**Technology of Trek: Computers and Software **

## Trek AMD Alias and SolidWorks

- Partnerships:
- Hardware
- Software
- CAID
- CAD

## Drawing Tools

- Tools:
- Wacom Cintiq
- Tablet PC

## Design Process

**Design at Trek**

## Fast Trip to ACG-MOVIE

**ACG:**
**Advanced**
**Concept**
**Group**

## Design Process

**ID defined by the Industrial Designers Society of America**

**What is Industrial Design?**

**	****“...****the professional service of creating and developing concepts and specifications that optimize the function, value and appearance of products and systems for the mutual benefit of both user and manufacturer...”**

## Design Process

**Technology-** **design process**

**Major Projects**

**1998**
- Klein Carbon Mantra
**1999**
- Klein Quantum Pro
- OCLV Road Redesign
**2000**
- OCLV USPS Team Time Trial
**2001**
- Klein Adept Full Suspension
- OCLV TT Handlebars
**2002**
- USPS Team Time Trial
- OCLV Carbon Fuel** **
**2003**
- OCLV WSD Road
- OCLV  Madone Series
**2004**
- OCLV TT rev2
- Bontrager OCLV TT Fork
- OCLV  Madone Series

## Design Process

**Technology-** **design process**

**Project Team**

## Design Process

**Technology-** **design process**

**Mission Goals**

## Design Process

**Technology-** **design process**

**Timeline**

## Design Process

**Technology-** **design process**

**Brand**
**Form Language**

## Design Process

**Technology-** **design process**

**Product**
**Form Language**

## Design Process

**Technology-** **design process**

**Data**
**Collection**
**And **
**Research**

## Lance on design-MOVIE

**Lance:**
- on design

**Technology: Lance on design**

## Design Process

**Technology-** **design process**

**Add centerline drawing**

**Centerlines**

## Design Process

**Technology-** **design process**

**Sketches**

## Design Process

**Technology-** **design process**

**3D Models**

## Design Process

**Technology-** **design process**

**Finite **
**Element**
**Analysis**
**and**
**Weight **
**Predictions**

## Design Process

**Technology-** **design process**

**Aerodynamic**
**Predictions**

## Design Process

**Technology-** **design process**

**Digital Lance**

## Design Process

**Technology-** **design process**

**Molding Parts**

## Design Process

**Technology-** **design process**

**Frame Build**

## Design Process

**Technology-** **design process**

**Road Test**

## Lance TT Feedback-MOVIE

**Technology: Lance checks in**

**Lance:**
- Feedback in 2000

## What is the Tour de France?

**Tour De France**

## What is the Tour De France?

**Tour History **

**1903** the idea was to promote a magazine ***l'Auto***** **

**1919** ***l'Auto ***was printed on yellow paper and so the yellow jersey came to be

- 2003 **100****th**** **anniversary of the Tour

**Lance Armstrong** has won the tour **6** consecutive times

**Greg Lemond ** was the first American to win (won **3** times)

## What is the Tour De France?

- Prologue - July 5: Paris, Eiffel Tower - ITT, 6.5 km
-  Stage 1 - July 6: Saint-Denis/Montgeron - Meaux, 168 km
- Stage 2 - July 7: La Fert sous Jouarre - Sedan, 204 km
-  Stage 3 - July 8: Charleville M zi res - Saint Dizier, 167 km
-  Stage 4 - July 9: Joinville - Saint-Dizier TTT, 68 km
- Stage 5 - July 10: Troyes - Nevers, 196 km
- Stage 6 - July 11: Nevers - Lyon, 225 km
- Stage 7 - July 12: Lyon - Morzine, 226.5 km
-  Stage 8 - July 13: Sallanches - L'Alpe d'Huez, 211 km
- Stage 9 - July 14: Bourg d'Oisans - Gap, 184.5 km
- Stage 10 - July 15: Gap - Marseille, 210 km
-  Rest Day - July 16
- Stage 11 - July 17: Narbonne - Toulouse, 160 km
-  Stage 12 - July 18: Gaillac - Cap D couverte ITT, 48.5 km
- Stage 13 - July 19: Toulouse - Plateau de Bonascre, 197.5 km
- Stage 14 - July 20: Saint-Girons - Loudenvielle, 191.5 km
- Stage 15 - July 21: Bagnres de Bigorre -LuzArdiden, 159.5 km
- Rest Day - July 22
- Stage 16 - July 23: Pau - Bayonne, 197.5 km
- Stage 17 - July 24: Dax-Bordeaux, 178 km
-  Stage 18 - July 25: Bordeaux - Saint Maixent l'Ecole, 200 km
- Stage 19 - July 26: Pornic-Nantes ITT, 49 km
- Stage 20 - July 27: Ville d'Avray-Paris-Champs Elyses, 160km

**What is the Tour De France?**

**21 Stages**

**3**** weeks long**
**2**** rest days**
**Total: **
**3,395 kilometers **
**or**
**2110  miles**

**Location...**

## What is the Tour De France?

**Jesery colors... **

**Polka Dot:**
**Best Climber**
**Green:**
**Best Sprinter**
**White:**
**Best Young Rider**
**Yellow:**
**Tour Leader**

## What is the Tour De France?

**2004 US Postal Service Pro Cycling Team **

**Sidekicks...**
**26**** members**
**9**** tour riders**
**100**** bikes**

## Design Process

**21****st**** century bicycles**

## In the beginning...

**40 lb bikes**
**1 gear**

## Bikes of the Tour

## 2005 Madone Series-MOVIE

**Madone Series**

## The second worst thing...

- The second worst thing that can happen...

- Lance wins again.

**What next?**
- New sponsors...
- New designs...
- 7 Tour victories?

**Not unlike a movie... there is an end**

## Q & A