Start

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Start
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Sagan ride to work-MOVIE
SEE VIDEO IN WINDOW AT LEFT
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Sagan Intro

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

Michael Sagan Senior Designer/Technology Principal
2005 Trek Madone 5.9 USPS Team Colors
Introduction- Influences and History
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Batavia IL
Batavia, Illinois USA
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Co-workers

• Lance Armstrong 6 time Tour De France
• Champion

• Roland
• Green
• 2 time World Champion

Trek co-workers
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Concept to Victory
Hero Villans Sidekicks Location Special
Effects And of course Props
Concept to Victory
(part 6)
Not unlike a movie
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Design Process
Waterloo, Wisconsin USA
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Trek History
Mid 80s
Trek in 1976
Trek today
Introduction Waterloo, Wisconsin
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Digital Trek Movie-MOVIE
Digital Trek
Introduction a glimpse into Trek
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Domestic Brands
Trek today Domestic Brands
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Add European Brands and aftermarket catalog slide
Trek today European Brands, aftermarket
catalog and Nike
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Trek Brands-MOVIE
Brands Klein Lemond Bontrager Gary
Fisher Wrench Force TCG
Trek Intro other brands
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Design Process
Technology of Trek Materials
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OCLV defined
OCLV defined
"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."
By sandwiching a honeycomb of Nomex between
layers of OCLV produces a structure so rigid,
engineers can create just about any shape they
want.
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.
Jim ColegroveComposite Guru
Technology Carbon Fiber
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GSM defined
GSM defined
Technology Carbon Fiber
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55 vs 120
Cross sections Madone Top Tube
Both sections at same magnification
55 gsm material is used in construction of
satellites
55 gsm OCLV
120 gsm OCLV
Technology Madone Top Tube
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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.
Technology Future Materials
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Trek on The Lance Chronicles-MOVIE
Trek On OLN
Technology a closer look at Trek
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Design Process
Technology of Trek Computers and Software
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Trek AMD Alias and SolidWorks
Partnerships Hardware Software CAID CAD
Technology- hardware and software
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Drawing Tools
Tools Wacom Cintiq Tablet PC
Technology- 21st century tools
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Design Process
Design at Trek
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Fast Trip to ACG-MOVIE
ACG Advanced Concept Group
Fast Trip to ACG
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Design Process
ID defined by the Industrial Designers Society of
America
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
What is Industrial Design?
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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
Technology- design process
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Design Process
Project Team
Technology- design process
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Design Process
Mission Goals
Technology- design process
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Design Process
Timeline
Technology- design process
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Design Process
Brand Form Language
Technology- design process
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Design Process
Product Form Language
Technology- design process
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Design Process
Data Collection And Research
Technology- design process
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Lance on design-MOVIE
Lance on design
Technology Lance on design
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Design Process
Centerlines
Add centerline drawing
Technology- design process
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Design Process
Sketches
Technology- design process
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Design Process
3D Models
Technology- design process
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Design Process
Finite Element Analysis and Weight Predictions
Technology- design process
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Design Process
Aerodynamic Predictions
Technology- design process
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Design Process
Digital Lance
Technology- design process
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Design Process
Molding Parts
Technology- design process
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Design Process
Frame Build
Technology- design process
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Design Process
Road Test
Technology- design process
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Lance TT Feedback-MOVIE
Lance Feedback in 2000
Technology Lance checks in
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What is the Tour de France?
Tour De France
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What is the Tour De France?
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
Greg Lemond was the first American to win (won 3
times)
2003 100th anniversary of the Tour
Lance Armstrong has won the tour 6 consecutive
times
Tour History
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What is the Tour De France?
Location
21 Stages
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
3 weeks long 2 rest days Total 3,395
kilometers or 2110 miles
What is the Tour De France?
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What is the Tour De France?
Polka Dot Best Climber Green Best
Sprinter White Best Young Rider Yellow Tour
Leader
Jesery colors
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What is the Tour De France?
Sidekicks 26 members 9 tour riders 100 bikes
2004 US Postal Service Pro Cycling Team
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Design Process
21st century bicycles
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40 lb bikes 1 gear
In the beginning
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Bikes of the Tour
2004 Bikes of the Tour
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2005 Madone Series-MOVIE
Madone Series
2004 Bikes of the Tour
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The second worst thing
What next? New sponsors New designs 7 Tour
victories?
The second worst thing that can happen
Lance wins again.
Not unlike a movie there is an end
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Q A