Another carbon fiber project to design and create a bottle holder for behind the seat. 3D printed mould and used 8 layers of 220g 2K Carbon fiber for the wet layup.
DIY: Carbon Fiber Bottle Holder
Category: DIY
DIY: Carbon Cockpit for Speedmax
My next foray into Carbon fiber design, tooling and development came with this project. Overall, a reasonable success. Still not perfect, and probably will not be used due to the catastrophic risk associated with riding a bike at 50mph and these breaking, but in theory and practice, a great learning opportunity.
Inspiration
Part 1: Prototyping
Part 2: Design
Fusion 360 for the design work.
Part 3: Tooling/Plug
This consisted of 4 3D printed cubes glued together and then finished with lots of sanding, and an epoxy coat.
Part 4: Version 1
The first version didnt go according to plan, I ran out of Carbon fiber material, and also recognized some layup issues. I decided to finish it anyway, but it was a dud 🙁
DIY: Canyon BTA Mount
A bit of a clone from other designs on the market for a BTA bottle mount which has an adjustable angle. Made for the Canyon Speedmax. Printed, but not field tested, shortly after I switch to work on OpenAero designs.
OpenAero – A open source design system for Bike Accessories
After designing, building, rebuilding, and re-printing dozens of accessories for my bikes over the last few years, I wanted to create and share a open source design system for accessories for bikes that allows myself (and a community) to innovate and collaborate on these types of products. Here is a snippet from the readme file:
Our goal is to develop a modular mounting system for bicycle accessories — ranging from water bottle holders and lights to phone and cycling computers. Partially inspired by Gridfinity, this system provides a base platform and is intended to be stackable. The motivation behind the definition and open source nature of this project is to encourage community-driven design and innovation in the triathlon space.
DIY – Canyon Garmin Mount
My second CNC project on the Carvera Air is a Garmin mount for my MTB. I have 3D printed these in the past, but thought it would be a good introduction to CNC. I also made a small water bed to cut the Carbon Fiber in to avoid the nasty dust which is generally made when cutting or sanding it. Fun weekend project!
Things can and did go slight wrong 🙁 This is what happens if the glue does not hold!
DIY – Canyon stem spacer
A carbon fiber project to recreate a Canyon spacer from plastic to CF.
Carvera Air CNC
Super stoked to have finally received the Carvera Air which I ordered on Kickstarter about 9 months ago!!! After doing a bunch of 3D printing and laser cutting with the Glowforge, I really wanted to test/try out CNC’ing and see what I could learn and build with a small desktop machine. I have been considering this for probably 4+ years, but never found the right machine or the intention to spend the money. Last year I decided to pull the trigger and after a long wait it finally arrived 🙂
First project was building a couple small parts to understand the workflow which I think turned out great. Overall, I am already really impressed. I think I will be constrained by the bed size, but will cross that bridge when I get to it 🙂
Aero Bottle Cover
A fun 3D print to Carbon Fiber project.
Designed in Fusion 360, 3D printed a mould and did a wet layup in Carbon Fiber. Pretty happy with the way it came out and impressed it held up even on the really rough NZ chip sealed roads!
There was a lot of trial and error on this due to the deep cavity and needing a vacuum to hold the material in place.
Carbon Fiber Arm Rests
This is my second pass at producing something strong enough and reliable enough to put onto my triathlon bike, and in this case some carbon fiber arm rests. My current arm rests pretty much did the job but at 300+g for the set, it seems like an easy win to reduce weight by making something similar out of CF.
The design for these took quite a lot of time, lots of trial and error and mistakes along the way 🙂 Cardboard cutouts, angles and long prints were the most tedious aspects, but ultimately I think they came out OK in the end.
Ideation and prototyping Steps
Tool/CAD Design
Mould 3D printing
These moulds had various finishes I was testing, everything from raw prints to epoxy coated.
DIY – “Forged” Carbon Fiber
After having some reasonable success in #D printing moulds and doing some layup in CF, I thought I would attempt a “forged” CF version of a part I have 3D printed in the past. Unfortunately it didn’t quite go according to plan, it ended up weighing close to 4 x more than the basic version. A fun experiment none-the-less!
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