Development Process: FlexBase Mounts
Traditionally, bicycle mounts for bike computers, also those that attach to the top tube, have been made from rigid plastic. The primary focus has been on ensuring a solid click mechanism for the computer. The method of adhering the mount to the frame has been a secondary consideration. Typically, there are versions of the product designed for flat and round frames. However, each frame type is unique in its flatness or roundness. So, why settle for a compromise when both the click mechanism and adhesive are equally important? This dilemma sparked the inception of the FlexBase Mount project.
The concept was clear: "No compromises". We embarked on a quest to find a manufacturing method for a flexible base plate "FlexBase". Our initial prototypes were crafted using hobby printers. Material was built up layer by layer through extrusion of tiny tracks. However, we quickly realized that while the hobby printer method worked, it resulted in a surface texture that was less than ideal. In the realm of extrusion printing, especially with TPU, results were still far from those of industrially manufactured parts.
Thus, we pivoted our manufacturing process and embraced additive manufacturing. This meant continuing with 3D printing but in an industrial context. The base plate is now produced using the Multi Jet Fusion process, in collaboration with a manufacturing partner in southern Germany. The object is built up layer by layer, achieving a significantly higher material quality through precise binding technology in the powder bed. The end results are impressive and comparable to injection molding processes used for high quantity production.
The selection of plastic inserts, in which you click your bike computer, also posed a significant challenge. We encountered various issues: weak click behavior, noticeable play between the device and the mount, or simply a lack of the quality we sought.
Choosing the right adhesive tape was also more complex than anticipated. There are numerous types, thicknesses, and, most critically, counterfeit products are prevalent online.
Our journey to transform our concept into a marketable product was far from straightforward. We dedicated ourselves to addressing each issue until we were completely satisfied. Our development process involved multiple iterations, continuously testing different design patterns and materials such as plastic inserts, screw combinations, and 3M VHB adhesive tapes. Over the past few months, we have gradually approached the finished product, which we initially expected to be ready for sale within a month.
The end result is the FlexBase Mount, a bike computer mount that adheres to any bicycle frame. The TPU we use adapts perfectly to any frame shape and is simultaneously tear-resistant and durable. The strong and permanent adhesive strength is ensured by the slim 3M VHB. In combination with the maximum flat design of the base plate, there is a minimal build-up from the device to the bicycle frame. The solid click mechanism is ensured by the use of a high-quality PE insert.
With our product, we are setting a new standard for bicycle accessories that are attached with adhesive technology. This not only offers an innovative solution but also opens up a variety of new possibilities for further products.
We look forward to presenting you with more ideas in the future. As passionate cyclists, we eagerly await any feedback (contact form) from you. With your help, we can perfect the quality of our products and provide real added value.
In this spirit - FEUA!
