Bike Beverage Holder
Bike Beverage Holder
Embedded Files
Design for Manufacture Practice Through Development of Bicycle Beverage Holder
Design for Manufacture Practice Through Development of Bicycle Beverage Holder
Role: Fabrication Lead, Physical Design Lead
Tools: CAD, GibbsCAM, Machine Shop, Resin Casting
Timeline: January - June 2024
The Bicycle Beverage Holder is a lightweight, durable beverage holder for cyclists to safely commute with a beverage- worry free. The product easily attaches to any bike’s handlebar and fits most beverages, from a cans to glass bottles to coffee cups.
The emphasis of this project is the iterative process of design and manufacturing and detailed documentation of the prototype to production process.
The scope of this project was to bring the product from ideation to mass manufacture in 15 weeks, while only using 1 purchased part and operating within a $400 budget for all supplies and possible necessities.
In a team of 4, we began by conceptualizing various possible methods to carry beverages on a bike. From more than a dozen ideas, we first chose a 6 pack design to optimize storage and functionality. However, in the manufacturing planning stage, we pivoted to a single beverage holder, in order to optimize manufacturability and prioritize real usability.
Concept Development From Sketch to Final CAD
Concept Development From Sketch to Final CAD
The initial brainstorming for the product...
The initial brainstorming for the product...
Turned to a first CAD model...
Turned to a first CAD model...
... Continued improvements to address manufacturability and feasibility
... Continued improvements to address manufacturability and feasibility
Final CAD Assembly of the Bike Beverage Holder, which accommodates a variety of cup sizes, holds the beverage firmly, is durable and lightweight, and reliably withstands shocks and bumps.
Final CAD Assembly of the Bike Beverage Holder, which accommodates a variety of cup sizes, holds the beverage firmly, is durable and lightweight, and reliably withstands shocks and bumps.
Through processes of study, trial, and error, we attempted multiple manufacturing processes. To create the aluminum handlebar clips, I invested 40+ hours in the BU Engineering Product Innovation Center (machine shop), to thoroughly learn GibbsCam and operate a 5 axis CNC Mill. The cup holder part required multiple iterations of 3D printed patterns to make silicone molds, filling the molds with resin, and testing the resin cast product.
Developing a Resin Cast Protocol to Simulate the Mass Manufacturing Process
Developing a Resin Cast Protocol to Simulate the Mass Manufacturing Process
The resin casting process: printing 3D printed forms, creating silicone molds, filling the molds with resin, and testing the resulting product. We only found the right materials and methods after 5 rounds of failed products!
Creating a Mass- Manufacture-Ready Metal Fabrication Process Using a CNC Machine
Creating a Mass- Manufacture-Ready Metal Fabrication Process Using a CNC Machine
The manufacturing process for the handlebar clips: GibbsCam design, CNC Milling, post processing, and assembly. Hands on learning at its best. Many many many failed attempts were required in this process.
Professional Documentation (RASCIIs, BOMs, etc)
Professional Documentation (RASCIIs, BOMs, etc)
Additionally, we employed tools including drill presses, machine sanders, and band saws to perform additional processes. All throughout the semester, we documented every plan and progression associated with the project, such as Tooling Plans, Control Plans, Specifications Documents, and RASCIs.
As important as the physical product, this project emphasized the documentation and planning involved in bringing a product from ideation to production. Shown here are the tooling plan, one of many important production documents (left) and proposed packaging design, an essential part in delivering products to customers (right).
10 Identically Manufactured, Ready to Ship Bike Beverage Holders
10 Identically Manufactured, Ready to Ship Bike Beverage Holders
The deliverables of this project included 10 identically produced bike beverage holders, a fully functional plan to manufacture thousands of the product, all theoretical relating parts and plans relating to production and sales, and precise documentation of every step involved in development. The finished Bike Beverage holder was able to safely carry cups up to 3.2 inches in diameter and 2.2 lbs in weight. Testing proved it could withstand potholes, rain, and outdoor use with less than 2% failure rate. This project truly challenged me to take responsibility outside of pure engineering and learn from at the entire process of product realization.
10 identically manufactured Bike Beverage Holders. One of my proudest accomplishments!
Page updated
Report abuse