3D PRINTED STAINLESS STEEL BICYCLE GRIP - HANDCRAFTED LEATHER STRAP
INTRODUCTION
We develloped Polygrip as an experimentation of different materials and manufacturing processes. It thus mixes the technology of 3D printing and the crafting of Leather. The exploration of making from 3D printing in stainless steel creates opportunities for the future of design. Moreover, we manufactured Polygrip to be as sustainable as possible. We reused old belts to create the leather straps that tell a story. We also collaborated with a unique craftmans like Tom Farrah.
Contents
Market Research
THE USERS & THEIR BIKES
This research was established using the matrix made in the streets of Melbourne. The panel of 100 bikes was chosen randomly in different areas of the city. Its purpose is to clearly define the number of users per handlebars and types of grips.
BEYOND THE NUMBERS
Measuring bicycle handlebars and grips type
Flat Leather Grip
Rubber Grip
Ergonomic Grip
9% Most Melbourne bicycles have a flat bar with rubber grips. It is justified by the minimal cost of those accessories and the fact that they are a standard in bicycle design. A few users have ergonomic grips, others choose the leather tape and some others have brighlty coloured grips. The wide variety of grips while the low design qualities make customisation a viable option for a designer.
GRIPS CATEGORIES Bicycle grips can be divided into 4 categories
Those who care about comfort and ergonomics for long rides and firm hold, they don’t mind spending a little more money. Those who want something cheap and colourful, easily removable, it makes their bike fun looking. The one that only swear by the classiness of leather. Makes their bike look sophisticated. The one that like the idea of using natural materials such as cork or wood. The environment is the reason why they ride a bicycle.
Ergonomics Du ra
bili
e
ty
l Sty
y
Co st
c ien
c Effi
Du ra
Du ra
bili
e
ty
l Sty
y
Co st
c ien
c Effi
Customisation
Customisation
Ergonomics
Ergonomics
bili
e
ty
l Sty
y
Co st
c ien
c Effi
Ergonomics
Customisation
Du ra
bili
e
ty
l Sty
y
Co st
c Effi
c ien
Customisation
Sketches development
A study of ergonomics and shapes
148
째
Do w
nw ar
d fo
rce
Our Values WHAT WE CARE ABOUT
When creating a new product, we always start by clearly defining what we really care about. For this project, we wanted to mix different elements, the exploration of 3D printing boundaries as well as the quality and labour of leather crafting. As for materials, we decided to use as much recycled materials as possible, to create a new user customisation experience.
3D Printing technology The exploration of emerging technology We wanted to explore the world of 3D printing, but we wanted to design an object that was only printable. The complex shape of interlocking polygons that is both futuristic and self supporting was perfect for 3D printing. It is thin and light, but incredibly strong and durable.
Durable & strong stainless steel structure Energy-efficient manufacturing process Product easily customisable for mass
Handcrafted leather The quality and style of a unique product Leather and bicycles go along well. They are two very disctinctiveobjects that complement each others. We believe a bicycle emphasize the quality of leather and vice versa. With the collaboration of Tom Farrah, we created a unique product that takes time to fabricate but that will last a lifetime.
3D printing & leather crafting
An interesting contrast of processes
We like the juxtaposition of materials and styles. 3D printing and leather crafting may be completely opposite, they still convey a strong balance. Here are some interesting facts about both processes.
LEATHER has been around for 3000 years, researchers have found that leather garments were commonly used in ancient Egypt.
3D PRINTING was invented in the 1980’s but started to be commercially available quite recently.
Leather making is a slow process, from raising the animal to tanning the product, then crafting it to create product. It takes more than 4 hours to make a wallet.
3D printing is sometimes reffered to rapid prototyping, indeed, it is considerably faster than regular manufacturing processes. A chess piece made of plastic takes around one hour to print.
A quality leather product can last a lifetime. Not only, leather is a tough material but it survives through trends and other obsolence. A weared out leather piece is actually considered as more valuable than a new one.
3D printing as well as modern technologies grow very quickly, they tend to become obsolete and are more subject to trends. An average american replaces their smartphones at least once every two years.
RECYCLING Made from recycled leather belts We looked around to source leather and it didn’t take us long to realize how easy it was to find free offcuts from local markets. There are a lot of belt makers at the Queen Victoria market that were happy to give away their belts offcuts. Belts carry the story of their previous owners. We reused them to write our chapter and carry a new load.
“Out of the 1 900 000 tons of finished leather produced in the year 1996, 805 000 tons of waste were made. 154 000 tons of which could have been reused into smaller products.� UNIDO
Consumer customisation
Making a product for everyone of us By using the advantages of 3D printing and a production process that was easy enough to dissasemble, we arrived to a unique product that everyone can personalize to their taste and needs. We believe that the experience of buying a bike should be the same as buying a car or a pair of new shoes.
The Process
HOW WE REINVENTED THE GRIP From first sketches to CAD, from 3D printing stainless steel to embossing leather. Let us walk you through the backstage of creating such a refined product.
Cost 1 $
4/ Cost 9 $
5/ Cost 13 $
1/
Cost 55 $
3/ Cost 29 $
2/
Cost of Labour : 9 minutes
1/ 1/ CAD model of the design in Solidworks. The edges are fileted to provide strenghts and all adjustments are made prior to printing.
Cost : 55 USD
2/ The printer deposits layers of stainless steel powder. Each layers are 30 microns thin. After this state the model is still very fragile.
3/ The model is then infused with bronze spray in a curing oven for a period of over a day. This method hardens the model to a solid piece of metal.
3/ The model is then both tumbled polished and high mirror polished manually to provide brightness and increases visual value for customers.
2/ 1/ The leather is cut to size either manually or by laser cutting. The laser cutting is faster but burns edges that need to be sanded down.
2/ The leather edges are then dyed with a special ink. It protects the edges from roughing up and keep it clean and weatherproof.
3/ A special tool was made on a 3D printer out of stainless steel to emboss the leather with custom logos or text. It is embossed using an hydraulic press.
4/ For a different feel and cheaper customisation. The leather can be laser etched with logos and text. It burns the leather and darkens it.
22.70
89
112
22.70
Gabriel Morisson Copyright Steppenwolf Design 2014 UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS
STAINLESS STEEL GRIP OPT 1 & OPT 2
Approved Factory Operator Final check Weight :
Materials :
Scale 1:1
Sheet 2 to 2
A4
22.70
18.75
7.80
Thread M6
22.70
19.30
21.25
5
Gabriel Morisson Copyright Steppenwolf Design 2014 UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS Approved Factory
STAINLESS STEEL SUPPORT PART 1 & 2 (INT/EXT)
Operator Final check Weight :
Materials :
Scale 1:1
Sheet 1 to 2
A4
Mass Customisation
A NEW USER EXPERIENCE
This research was established using the matrix made in the streets of Melbourne. The panel of 100 bikes was chosen randomly in different areas of the city. Its purpose is to clearly define the number of users per handlebars and types of grips.
You can customise which handlebar suits your needs, which grip design, its materials, its size. Choose wether or not, you need brakes, or if you prefer embossed or etched leather grips.
We wanted to create a product easily customisable to make a better product that targets a wider audience. Buying a bicycle is a little bit like buying a car or a pair of new shoes. Users tend to build a certain relationship with those kind of products, it becomes more than an object. We wanted our bicycles to represent its users and since everyone has a different taste, customisation is the best option for a unique product.
GRIPS
STRAPS
. Colour . Colour . Material . Material . Size . Etching
BRAKES
. Types
A GREAT BUYER EXPERIENCE
4.9 Thanks for rating us !
Uses scenario Understanding user experience We designed the straps for the users. To simplify our daily lives is what we work for. Who has never put stuff on their handlebars ? A bag ? A helmet ? A lock ? We have all done it, and it certainly isn’t the best place to put them. So let’s at least design it well.
When you are not carrying anything, just let the strap rest from carrying heavy loads. The strap is fitted with a special screw that prevents to move while you are riding. It also protects your grip from scratches and being damaged if your bicycles falls over.
As soon as you need to carry something, simply pivot down the strap. Unscrew the specially designed locking mechanism and place your belongings. It is secured, fast and can carry a pretty heavy load.
Human factors Ergonomics and technical aspects We designed the straps for the users. To simplify our daily lives is what we work for. Who has never put stuff on their handlebars ? A bag ? A helmet ? A lock ? We have all done it, and it certainly isn’t the best place to put them. So let’s at least design it well.
Stainless steel is highly corrosion resistant because it contains a lot of chromium. It thus has sanitary qualities, which means it is self cleaning as well as being low maintenance.
107 mm
23
Strong contact points
Using Stainless steel as the grip material makes sense because a bike spends so much time outside. The grip pattern makes gripping easier because your flexible skin is held in place by the negative space.
PACKAGING Clean, simple and colourful
Leather strap
Made from the standard cardboard box 0427. The packaging is 120 x 80 x 80 mm. It can fit up to two grips and two straps. It was designed to use the best volume possible without wasting any space. In a 40 ft container, you would be able to fit 80.000 of those boxes which would make shipping cheaper. The leather strap adds an exciting piece to take out when opening the packaging.
Assembly HOW TO PUT IT TOGETHER
We wanted a product easily customisable but also very strong. The grips needed to be interchangeable and the whole assembly almost unnoticeable and flush.
1//
E
D
B
C
2//
With the allen key included, tighten the grub screw into the hole. This action will fasten the handlebar to the grip. If you are assembling the grip and the brake, make sure you fit the brake cable inside the grip and into theopening of the handlebar.
The Collaboration THE ART OF CRAFTING LEATHER
We had the chance of collaborating with the very talented leather craftman, Tom Farrah of Farrah design. Tom has been working with leather for a long time and taught us a few tricks to create a high quality object.
“I just love the material, to me the hide of an animal is something that should be respected and therefore not cut or stitched unnecessarily. I tend to think that the material alone is capable of solving far more of the design problem than we give it credit for, we just have to think about how to manipulate it.�
Tom Farrah