Frame Story - Bicycle Frames Long Term Design Research

Frame story- Bicycle Design Research 

The Frame Story project, initiated in 2012, encapsulates over a decade of research, creation, and development in a small "tiny factory" workspace. This project chronicles the design and production of 21 bicycle frames, showcasing diverse materials and technologies used in local, self-sufficient manufacturing under varied scenarios. The project explores the designer's role in the context of digital manufacturing, accessibility, and online platforms. Through the lens of bicycle frame development, it addresses questions about manufacturing processes, social and environmental responsibility, economic accessibility, and the intersection of technology and design.

 Frame 001 

"The bicycle is the noblest invention of mankind." — William Saroyan 

The Experimental Mobile Lab

Frame 001 laid the foundation for the project's exploration of natural composites and low-cost manufacturing techniques. Built from cork, bamboo, and unwoven flax fibers, the frame represented the first step in testing sustainable materials for bicycle construction. Bamboo contributed tensile strength and shock absorption, while flax fibers reinforced critical stress points. Cork, though unconventional, was assessed for its potential to dampen vibrations and improve ride comfort.

Due to limited resources, the frame's assembly relied on a makeshift jig constructed from a repurposed IKEA table and generic metal parts typically used in woodworking. This improvised setup reflected early efforts to create accessible fabrication tools without industrial-grade infrastructure. Despite its simplicity, the jig ensured precise tube alignment, enabling the frame to endure rigorous testing in real-world conditions.

The frame was designed for aggressive fixed-gear riding, subjecting it to high acceleration and intense braking forces. This stress testing allowed the bicycle to function as a mobile research lab, where ongoing fiber pattern adjustments informed optimization strategies. Iterative experimentation with layering techniques and tube arrangements provided crucial insights into balancing strength and weight efficiency, establishing a basis for future material innovations and design refinements.

Frame 001 exemplified the project's ethos of craft technology, blending natural materials with DIY fabrication to push the boundaries of what could be achieved with minimal resources. These early efforts reinforced the potential for personalized, sustainable design to thrive within a decentralized, low-footprint production model.

                                                    Frame 002                                                                            

 "When the spirits are low, when the day appears dark, when work becomes monotonous, when hope hardly seems worth having, just mount a bicycle and go out for a spin down the road, without thought of anything but the ride you are taking." — Arthur Conan Doyle

Hybrid Bamboo Frame with Digital Precision

Building on the foundation of Frame 001, Frame 002 introduced a new construction method by blending bamboo craftsmanship with digital fabrication. This frame featured 3D-printed connectors, produced through fused deposition modeling (FDM), to precisely align the naturally variable bamboo poles. These digital components addressed a critical issue in bamboo construction: the inherent inconsistencies in tube shape and size, which often complicate manual alignment.

The introduction of these connectors led to a significant evolution of the jig. A hybrid approach was adopted, where parametric design informed the production of customizable jig elements that could accommodate different frame geometries. This enabled greater control over alignment tolerances, improving both structural integrity and ride quality.

Once assembled, the frame was reinforced with flax fiber laminates, ensuring that the joints remained strong and flexible under stress. The integration of craft-based material and machine precision demonstrated how technology and tradition could coexist to enhance both performance and aesthetics. Frame 002 laid the groundwork for further digital-modular manufacturing systems, which would become central to the project’s evolution.

Frame 003 

"Bicycling is a big part of the future. It has to be. There’s something wrong with a society that drives a car to work out in a gym." — Bill Nye 

Parametric Modularity with Hemp Epoxy Composites

Frame 003 expanded on the digital integration seen in Frame 002 by adopting parametric design principles to create a fully modular jig. This iteration focused on enabling rapid customization of frame geometry, which was achieved through adjustable 3D-printed jig components. Using dedicated CAD software, builders could modify key parameters such as tube angles, lengths, and diameters to create frames tailored to individual rider specifications.

The frame was constructed from pre-treated bamboo poles and 3D-woven hemp epoxy composites. The choice of hemp fibers, known for their high tensile strength and flexibility, reinforced the frame’s joints, allowing for improved shock absorption. This frame demonstrated that open-source parametric systems could democratize the frame-building process, enabling small workshops and independent builders to create frames without costly infrastructure.

The parametric jig system was a major milestone in the project, representing a modular philosophy that would continue to influence subsequent designs. It underscored the project’s vision of accessible manufacturing, where both performance and customization were prioritized.

Frame 004  

"Think of bicycles as rideable art that can just about save the world." — Grant Petersen 

10 speed drive-train and internal routing 

Frame 004 emphasized fiber lamination as both a structural innovation and an aesthetic feature. To support this approach, a new one-sided jig was developed, improving the efficiency of fiber reinforcement application. This advancement ensured better tube alignment, layer control, and a reduction in production time, essential for both durability and performance.

Designed for a heavy-duty mountain bike, the frame was built to handle intense off-road conditions. It was the first 10-speed frame developed in the project, which necessitated a redesign of the rear dropout to accommodate the drivetrain configuration. Additionally, the frame integrated a disk brake system, further shaping the dropout design to meet both braking and drivetrain alignment requirements. These changes enhanced the frame's modularity and adaptability for various cycling setups.

A significant feature was internal cable routing, which provided both functional and visual improvements. Cables were routed through the frame’s interior, minimizing external clutter, reducing exposure to environmental elements, and improving the bicycle’s aerodynamics. This design choice increased long-term durability by protecting cables from wear and tear, while also reducing maintenance needs.

The fiber lamination process enabled the creation of subtle visual textures, resulting in a frame that blended artistic craftsmanship with engineering precision. By experimenting with layering techniques, designers enhanced the aesthetic value of the frame without compromising its structural performance. This iteration reinforced the project’s mission of merging technical innovation with design creativity, offering a blueprint for bicycles that excel in both function and form.

Frame 005

"Every time I see an adult on a bicycle, I no longer despair for the future of the human race." — H.G. Wells

Travel-Friendly Knockdown Frame

Frame 005 was driven by the need to solve the logistical challenges faced by cyclists traveling internationally, particularly the restrictive airline baggage policies that can make transporting bicycles expensive and cumbersome. This frame introduced an innovative knockdown mechanism that allowed the entire frame to be disassembled into multiple segments. Once dismantled, the frame could fit within a standard suitcase measuring less than 60 cm in length, enabling cyclists to avoid oversized luggage fees.

The structural design relied on eight disengagement points, strategically placed to maximize stability while ensuring that reassembly was quick and intuitive. These points were located on key joints, including the rear triangle, top tube, and fork area, making the frame both portable and durable. The frame was made from bamboo poles, chosen for their natural shock absorption properties, and reinforced with a composite blend of hemp and flax fibers to enhance strength without adding excessive weight.

To address the unique demands of this modular design, a specialized jig was developed. This jig ensured precise alignment of the tube segments and joints during both assembly and disassembly, maintaining tight tolerances necessary for structural integrity. The jig also featured 3D-printed guides to control tube placement, accommodating minor variations in bamboo pole dimensions.

The frame underwent extensive field testing to confirm that the modular joints could withstand repeated assembly cycles without degradation in performance. These tests included vibration stress tests, dynamic loading during travel, and long-distance rides on varied terrain. The results demonstrated that the frame retained its rigidity and handling characteristics even after multiple breakdowns and reassemblies, offering a reliable solution for frequent travelers and touring cyclists.

Another challenge addressed by the design was the integration of cable routing through modular frame segments. Detachable quick-release connectors allowed cables to remain in place when the frame was reassembled, minimizing time spent on adjustments and tuning.

In addition to its functional innovations, Frame 005 represented a significant shift in the project's design philosophy, emphasizing the importance of modularity and adaptability in modern bicycle construction. It illustrated how bicycles could be designed to meet practical travel needs without compromising performance. Cyclists who frequently moved between urban and rural environments found the frame particularly appealing, as it combined convenience, transportability, and sustainability.

This iteration showcased the project's continued exploration of localized manufacturing, where custom jigs, modular joints, and composite reinforcements could be tailored for users with specialized needs, further expanding the possibilities for highly adaptable frame systems.

Frame 006 

"When I got the bike I must have been the happiest boy in Liverpool, maybe the world." — John Lennon

Style-Driven Innovation with 3D-Printed Components

Frame 006 pushed the boundaries of digital fabrication by focusing on the aesthetic and structural integration of 3D-printed components. Custom-designed cable mounts and frame joints provided a fresh take on frame design, emphasizing both visual harmony and performance optimization. Unlike previous frames, this design did not use internal cable routing but instead showcased external cables, securely mounted through precision-printed brackets that added subtle, stylistic elements to the frame.

The design experimented with non-traditional tube geometries, facilitated by 3D-printed joints that supported asymmetric arrangements. These configurations allowed designers to optimize both stiffness and weight distribution, enhancing the frame’s performance without sacrificing its sleek, modern aesthetic.

The iterative prototyping process—enabled by additive manufacturing—allowed for rapid adjustments and improvements in both functional and stylistic elements. This process minimized material waste and accelerated development timelines, making it easier to experiment with complex geometries and custom features.

By blending digital precision with design creativity, Frame 006 demonstrated the potential for additive manufacturing to elevate both style and function in bicycle frames. It underscored the versatility of digital-first design, highlighting its scalability for both small-batch production and custom projects.

Frame 007

"The advantages? Exercise, no parking problems, gas prices, it’s fun. An automobile is expensive. You have to find a place to park, and it’s not fun. So why not ride a bicycle? I recommend it." — Stephen G. Breyer

Symmetrical Modular Breakdown Frame

Frame 007 was designed to address the needs of cyclists who require both portability and high performance, particularly for travel and storage in constrained environments. Frequent travelers, including touring cyclists and urban commuters, often face issues with airline baggage policies and limited storage options. This frame introduced a symmetrical modular breakdown system that allowed it to be disassembled into identically sized segments, enabling it to fit inside a 60 cm travel case and comply with airline luggage requirements.

The symmetrical design reduced mechanical complexity by balancing stress distribution across matching parts. This innovation ensured that reassembly was consistent and precise, requiring minimal adjustments. To support this new approach, a custom jig was developed, featuring 3D-printed alignment tools that held each segment in place during both assembly and disassembly. The jig enabled repeatable precision, even after multiple breakdown cycles.

The frame construction prioritized a balance of lightweight flexibility and durability. Bamboo was chosen for its shock-absorbing properties and structural integrity, while recycled aluminum connectors reinforced the modular joints, allowing for seamless reassembly without compromising strength. Additional reinforcement in key stress areas was provided by hemp and flax fiber composites, which enhanced the frame’s longevity under repeated travel conditions.

Performance tests demonstrated that the frame retained its stiffness and handling performance, even under demanding riding conditions. Its design proved effective for both long-distance touring and daily urban use, offering a solution that merged versatility with ruggedness. External cable routing was maintained through adjustable modular mounts, which provided easy access for repairs and reduced the risk of cable damage during transport.

This iteration reinforced the project's commitment to adaptive frame design, offering a practical response to the growing need for mobility and flexibility in contemporary cycling. Frame 007 showcased how modular systems could expand the functionality of bicycles without sacrificing performance, making it a benchmark for future innovations in sustainable, portable cycling solutions.

Frame 008 

"Work to eat. Eat to live. Live to bike. Bike to work." — Unknown 

The Jigless Method – Redefining DIY Bicycle Frame Construction

Frame 008 introduced the Jigless Kit, an ongoing experiment in decentralized and customizable frame construction. The goal was to reduce reliance on traditional fixed jigs, which often limit design flexibility and require significant investment. Instead, parametric 3D-printed components were used to temporarily align the frame tubes, allowing for a more adaptable and iterative building process. The frame itself was built using aluminum tubes, chosen for their balance of strength and weight.

This method allowed frame builders to experiment with new geometries and tube arrangements without being constrained by permanent fixtures. The 3D-printed alignment parts could be modified on demand, making it possible to explore non-traditional designs with ease. Builders could print and adjust components locally, emphasizing a decentralized approach to production.

The project also focused on accessible material sourcing, integrating fiber reinforcements made from denim fibers (jeans). These materials, readily available and recyclable, were used to strengthen the frame's critical joints. This shift toward locally sourced fibers reflected a broader effort to incorporate sustainable practices into the construction process, though the results remain part of the ongoing research to improve frame durability and performance.

Field tests indicated that the frame maintained its alignment and stability under a variety of conditions, though further refinements are needed to optimize joint performance. The design continued to evolve, with additional testing of new materials and tube geometries.

The Jigless Kit has been a crucial component of the project's R&D initiatives, encouraging open experimentation and collaboration. By making the parametric designs for jig components available to other builders, the project aims to create a global platform for sharing design modifications and insights. However, this phase is still part of an iterative development process, with more improvements expected in future iterations.

Frame 008 represents a critical exploration of flexibility, accessibility, and sustainability in bicycle frame design. It has laid the groundwork for further innovations while contributing to a larger conversation about local production models and alternative material use in the cycling industry.

Frame 009 

"The best rides are the ones where you bite off much more than you can chew, and live through it." — Doug Bradbury 

Refining the Jigless Method and Composite Integration

Frame 009 marked a critical refinement in the jigless construction process, with a focus on tightening tolerance requirements to improve precision and alignment. As the jigless scheme evolved, it became clear that greater control over tube placement was necessary to ensure consistent performance. This led to a transition to off-the-shelf tubing, which offered standardized dimensions and better compatibility with the 3D-printed alignment components used in the jigless kit.

The shift to pre-fabricated tubes introduced new opportunities and challenges. While the use of standardized aluminum tubing streamlined production and reduced variability, it also necessitated further innovation in composite reinforcement techniques. The frame was designed with fiber laminate composites applied at key joints and stress points, which provided structural flexibility and customizable frame behavior. This approach enabled the bonding of different materials—such as metal and natural fibers—allowing the frame's stiffness, vibration absorption, and load distribution to be tailored to specific riding conditions.

One of the significant benefits of the composite reinforcement system was its material versatility. By adjusting the type and placement of fiber laminates, the frame could be optimized for different performance goals. For example, riders prioritizing comfort on long-distance rides could enhance vibration damping, while those seeking high-speed responsiveness could emphasize stiffness and power transfer. This level of customization highlighted the potential of composites to create adaptive frame designs that respond dynamically to rider needs.

The jigless method continued to evolve during this phase, incorporating tighter control over the dimensional tolerances of both the tubes and printed alignment components. Builders could achieve precise tube angles and joint stability, improving both the structural integrity and overall ride quality of the frame. The iterative nature of the process allowed for continuous experimentation, with each prototype informing further refinements in both materials and construction techniques.

Field testing confirmed that the frame performed well under diverse conditions, demonstrating stability and control even on challenging terrain. The project continued to emphasize sustainable material use by integrating fiber laminates derived from both recycled and locally available sources.

Frame 009 represents a key step in the ongoing development of the jigless system, advancing the balance between design flexibility and manufacturing precision. By blending standardized components with innovative reinforcement strategies, the frame underscored the project's commitment to creating versatile, performance-driven solutions for the modern cyclist.

Frame 010 

"If constellations had been named in the 20th century, I suppose we would see bicycles." — Carl Sagan

Modular, Inclusive Frame Design with Microstructure Jig Development

Frame 010 reimagined traditional bicycle frame geometry through a modular, inclusive design approach aimed at accommodating a wide range of riders. It was capable of adjusting to fit individuals between 140 cm and 185 cm in height, covering frame sizes from 47 cm to 57 cm. This flexibility made the frame suitable for diverse user needs, allowing for custom adjustments to enhance both comfort and performance.

The frame's construction was based on four modular core units, created from 3D-printed parts, aluminum connectors, and wooden poles reinforced with 100% cotton fiber laminates. This material combination provided a balance between lightweight durability and structural flexibility, making the frame both robust and portable. To facilitate disassembly and travel, the frame employed quick-release connectors, enabling the entire structure to be broken down and packed into a medium-sized backpack.

A key structural innovation was the use of a high-tension stainless steel cable to replace the traditional down tube. This cable contributed to vibration absorption and reduced frame weight, while maintaining the necessary tension to ensure structural integrity. The parallel alignment of the front and rear tubes further optimized load distribution, improving handling and stability on various terrains.

This iteration marked a significant transition in the project's manufacturing process with the development of a microstructure jig system. Instead of relying on a single large jig, each section of the frame was constructed using independent, small-scale jigs designed to precisely control the alignment and dimensions of individual components. Once completed, the modular sections were assembled into the full frame, ensuring high accuracy and adaptability without the constraints of a fixed jig. This approach offered enhanced flexibility in both design iteration and material experimentation.

Field tests confirmed that the frame maintained structural integrity across multiple assembly cycles, with riders praising its portability and ergonomic adaptability. The use of quick-release components allowed for rapid reconfiguration, making it ideal for scenarios where the frame needed to be transported frequently or shared among multiple users.

Frame 010 exemplified the project's broader vision of creating customizable, sustainable bicycles that could evolve with their users. By combining microstructure jigs, modular components, and sustainable materials, the design demonstrated how modern frame-building techniques could offer high performance, adaptability, and ease of use in a single cohesive package.

Frame 011 

"A bicycle ride is a flight from sadness." — James E. Starrs

Experimenting with Tube Material Dynamics

Frame 011 shifted focus from joints and connectors to the tubes themselves, investigating how changes in tube materials could influence ride quality. The tubes, as the main load-bearing and vibration-transferring elements, were seen as critical factors in determining the frame's performance. This iteration explored how material variations could optimize characteristics such as vibration absorption, stiffness, and handling responsiveness.

The frame incorporated fiber-reinforced composite tubes for better shock absorption, which aimed to smooth the ride over rough terrain. Conversely, stiffer tubes prioritized power transfer, making the frame more efficient in speed-focused scenarios. This approach provided a means to customize performance attributes without modifying the frame’s geometry.

Despite these material changes, the construction process adhered to a traditional jig system without introducing new modular assembly techniques. This allowed the focus to remain on tube composition and its impact on performance. The method demonstrated that material adjustments could be integrated into the frame-building process without complicating manufacturing.

This iteration emphasized the potential for adaptive frame design, where material selection plays a key role in shaping the cycling experience. Frame 011 contributed to ongoing research into customizable and performance-driven frames, reinforcing the idea that material innovation can enhance bicycle design without requiring major structural alterations.

Frame 012

"You don’t suffer, kill yourself, and take the risks I take just for money. I love bicycling." — Greg LeMond

Fiber Lamination with Used Army Uniforms

Frame 012 expanded the project's fiber lamination techniques by incorporating used army uniforms into the frame structure. These textiles, featuring camouflage patterns and patches, were embedded in the fiber layers to serve both structural and aesthetic functions. The materials added a layer of storytelling, symbolizing themes of resilience, history, and recycling.

To achieve this, a new jig design was introduced to ensure precise alignment of the laminated fibers and frame components. The jig allowed for greater control over fiber placement, supporting the lamination process's integration of non-standard materials like fabric. This innovation balanced structural integrity with visual expression, creating a frame that was both durable and unique.

The fabrication process focused on layering techniques that optimized weight distribution and impact absorption. The laminated uniforms reinforced the frame at critical points, enhancing flexibility without adding significant weight. This method demonstrated the adaptability of the lamination process to accommodate recycled and culturally significant materials.

The frame featured external cable routing, keeping the focus on fiber-based reinforcement and material integration. By blending textiles and natural fibers, the design achieved a harmony of functionality and personalization.

Frame 012 stood out within the project as a sustainable and innovative design, illustrating how bicycles can incorporate meaningful materials while maintaining high performance. This iteration emphasized the project's ongoing commitment to creative exploration in fabrication and material selection.

Frame 013 

"Life is like riding a bicycle. In order to keep your balance, you must keep moving." — Albert Einstein 

Custom Laminated Lugs with Zero-Waste Design

Frame 013 emphasized both personalization and sustainability through the innovative use of leftover textiles from a clothing shop. Various colors and patterns were embedded within the frame’s laminate layers, transforming fabric remnants into a crucial part of the frame's design. This zero-waste approach showcased how recycled materials could serve both aesthetic and structural purposes, aligning with the project’s focus on sustainable innovation.

The finishing process centered around laminated lugs, where printed and patterned fabrics were layered to create customized textures and visual effects. These laminates were reinforced with structural fibers, ensuring that the decorative elements did not compromise durability. This technique opened up endless possibilities for graphic treatment, allowing each frame to be tailored to the rider’s personal style.

To support this level of customization, the project transitioned to a jigless microstructure system. Instead of using a large, industrial jig, the frame was built with modular alignment tools designed for precision and adaptability. This shift significantly reduced the total manufacturing time—cutting it in half—while providing greater flexibility for integrating personalized materials.

The frame retained external cable routing, keeping the design functional and maintenance-friendly. By focusing on surface-level enhancements, the project demonstrated how aesthetic and practical needs could be seamlessly integrated. The incorporation of fabric remnants further reinforced the project’s commitment to zero-waste design.

Frame 013 exemplified the potential of customized, sustainable frame-building, offering a model where both creativity and eco-consciousness played vital roles. It served as a testament to how small material innovations can significantly impact the visual and functional identity of a bicycle frame, making each build a one-of-a-kind creation.

Frame 014 

"The bicycle is just as good company as most husbands and, when it gets old and shabby, a woman can dispose of it and get a new one without shocking the entire community." — Ann Strong

Laminated Textiles and the Oil-on-Water Effect

Frame 014 expanded on the lamination techniques developed in earlier frames but introduced a unique visual effect by incorporating quilt leftovers into the design. This frame aimed to merge functional reinforcement with aesthetic storytelling, using textiles in a way that resembled the shifting, iridescent colors seen in oil-on-water patterns. The diverse colors and textures of the fabric remnants added both visual complexity and structural depth to the frame.

The design process focused on achieving precision layering, where the textiles were strategically placed to create dynamic color shifts under different lighting conditions. These variations gave the frame a fluid, organic appearance, making each angle of the bicycle visually engaging. While aesthetically striking, the laminated fabrics were reinforced with natural fibers, ensuring that the design did not compromise strength or resilience.

A new jig refinement was introduced to handle the meticulous alignment required by the multi-layered lamination process. This jig provided precise control over tube placement, allowing the textiles to be evenly distributed across high-stress points. The integration of fabric layers contributed to both vibration absorption and structural stability, further enhancing the frame's ride quality.

The project maintained external cable routing, as the emphasis remained on the outer frame aesthetics and material customization. The cable mounts and other external elements were designed to complement the textural complexity of the laminated fabrics.

This iteration also reinforced the project’s commitment to sustainability through the use of fabric remnants, minimizing material waste while promoting creative reuse. The frame demonstrated how recycled textiles could add artistic value to functional objects, blurring the line between design and engineering.

Frame 014 exemplified the project's ongoing exploration of personalization and material innovation. The combination of visual storytelling, sustainable practices, and high-performance construction highlighted the potential for bicycles to serve as both practical vehicles and expressions of craftsmanship. This frame stood out for its playful, yet technically sophisticated use of textile laminates, offering a glimpse into the future of design-driven fabrication techniques.

Frame 015 

"The bicycle is a curious vehicle. Its passenger is its engine." — John Howard

 Display-Optimized Design 

Frame 015 further developed fiber lamination techniques, utilizing red flax fiber ribbons as a primary structural material. This frame focused on optimizing the way bicycles are displayed in exhibitions, balancing both aesthetic presentation and functional performance. To achieve this, brass tubes were integrated into the frame to create a suspension system that allowed the frame to be mounted using steel cables, giving the impression of the bicycle floating when showcased.

This concept aimed to maximize the frame’s visual impact in high-profile design events. The embedded brass tubes served as discreet yet robust anchors for the suspension cables, ensuring both stability and elegant symmetry when mounted. The result was a display system that highlighted the bicycle's craftsmanship, emphasizing both its technical and artistic qualities.

The red flax ribbons were chosen for their structural integrity, vibration-damping properties, and rich visual appeal. The lamination process was carefully refined to ensure proper alignment and tension, giving the frame a polished, cohesive appearance that complemented the brass detailing. This innovative material combination underscored the project's commitment to sustainable design, blending natural fibers with modern engineering solutions.

To support this new design, a custom jig was developed to ensure precise integration of the brass tubes and flax ribbons. The jig system maintained tight tolerances, optimizing both strength distribution and the visual symmetry required for exhibition purposes.

The frame featured external cable routing, allowing for clean maintenance while keeping the focus on the surface design and suspension system. The contrast between the bold red fibers and the polished brass elements enhanced the bicycle's sculptural presence, making it a centerpiece in exhibition settings.

Frame 015 was presented at the Contemporary Israeli Design Pavilion during Taipei Design Week, where it attracted attention for its innovative combination of display and structural engineering. The frame demonstrated how material innovation and contextual design thinking can transform bicycles into both functional and artistic objects.

This iteration highlighted the project's ability to adapt materials and fabrication techniques to specific contexts, reinforcing a vision where sustainability, customization, and presentation aesthetics converge in modern bicycle design.

Frame 016 

"Give a man a fish and feed him for a day. Teach a man to fish and feed him for a lifetime. Teach a man to cycle and he will realize fishing is stupid and boring." — Desmond Tutu

The Pajama Methodology and Decentralized Carbon Fiber Design

Frame 016 was developed with an unconventional approach called the "Pajama Methodology." The concept was simple yet ambitious: Could an entire frame production process be managed without leaving the workshop? This question led to a deep exploration of remote production strategies, relying heavily on international logistics and platforms like AliExpress to source materials and components. The experiment aimed to understand how designers could adapt to a world increasingly driven by global supply chains, decentralized fabrication, and remote collaboration.

For this iteration, the frame marked the project’s first foray into carbon fiber construction. This material, known for its high strength-to-weight ratio, posed both challenges and opportunities. The carbon fiber frame was designed with an integrated rear shock absorber, enhancing ride comfort and performance on varied terrains.

To further support portability, titanium couplers were integrated into the top tube and down tube. These couplers allowed the frame to be collapsible, making it easier to store and transport. The titanium components provided the necessary durability to withstand repeated folding and unfolding cycles without compromising the structural integrity of the frame.

The production process underscored the feasibility of remote material sourcing. Items ranging from carbon fiber sheets to specialized connectors were procured through international suppliers and shipped directly to the workshop. The reliance on global free shipping networks raised questions about the efficiency and sustainability of such an approach, but it also demonstrated how designers can tap into a decentralized supply chain to manage complex projects without on-site visits to factories or suppliers.

This frame also served as a testbed for integrating high-performance materials, such as titanium, within a modular frame design. The use of both carbon fiber and metallic couplers highlighted the project's ongoing efforts to combine lightweight construction with flexibility and transportability.

While the Pajama Methodology raised logistical and engineering challenges, it also pointed toward new possibilities in distributed manufacturing. Designers could theoretically manage entire fabrication cycles remotely, coordinating material acquisition and assembly through a blend of digital tools and global networks. The experience contributed valuable insights into how the design process itself might evolve in response to changing economic and technological landscapes.

Frame 016 demonstrated the project's ability to adapt methodologies to modern production realities, emphasizing remote logistics, sustainability, and innovation in frame design. This iteration reinforced the idea that bicycles can be both technological experiments and adaptive design solutions, shaped by the demands of an increasingly interconnected world.

Frame 017 

"The bicycle has done more for the emancipation of women than anything else in the world." — Susan B. Anthony

Orthopedic Casting Tape Experimentation

Frame 017 marked a pivotal moment in the Frame Story project by pushing the boundaries of material innovation. The idea emerged after a visit to an orthopedic clinic, where I have noticed orthopedic casting tape being used to stabilize fractures. This tape, designed to harden upon exposure to air, was lightweight, durable, and had a high degree of flexibility—qualities that sparked the idea of adapting it for bicycle frame construction.

To test this concept, casting tape rolls were ordered and used as tube connectors, replacing traditional epoxy laminates. The result was a frame with shock-absorbing joints that maintained structural integrity while reducing road vibration. The process proved to be fast and efficient; within minutes of application, the tape hardened around the frame's bamboo or steel tubes, bonding the materials together without the need for long curing times associated with traditional composite techniques.

Aesthetically, the casting tape was chosen in bright colors, particularly pink, to emphasize the experimental nature of the project. The porous texture of the hardened material also provided opportunities for custom decoration, enabling further personalization. Riders and collaborators were encouraged to apply designs or paint the frame, turning the structure into a canvas for artistic expression.

Functionally, the frame demonstrated flexibility under load, effectively reducing the transfer of vibrations to the rider. This innovation enhanced long-distance comfort, making the frame suitable for endurance riding on mixed terrain. Additionally, the material’s medical-grade properties ensured high durability, even under adverse environmental conditions like rain and mud.

This frame exemplified the project’s commitment to cross-disciplinary experimentation, where insights from medical technology were successfully adapted for industrial design. Frame 017 served as a powerful example of how unexpected materials could inspire new approaches to both performance optimization and creative design in bicycle manufacturing.

Frame 018

"Cyclers see considerably more of this beautiful world than any other class of citizens. A good bicycle, well applied, will cure most ills this flesh is heir to." — Dr. K. K. Doty

Polymer Pool Party

Frame 018, playfully titled "Polymer Pool Party," experimented with vibration control through the integration of polymer-filled 3D-printed connectors. Drawing inspiration from skeletal joints, the design sought to introduce a subtle but meaningful enhancement to ride comfort by absorbing vibrations at critical tube junctions. The goal was not to revolutionize the frame’s performance but to test how localized flexibility could improve energy efficiency and shock absorption.

The polymer material, housed in 3D-printed containers, acted as passive dampers, softening the frame’s response to road vibrations. This approach allowed for a more comfortable ride, particularly on uneven surfaces, while still maintaining the frame’s stiffness where needed for power transfer. By focusing on incremental refinement, the project underscored the value of small adjustments in shaping the cycling experience.

Fabrication centered on precision alignment, with the 3D-printed connectors designed to fit seamlessly over the frame’s tubing. This method offered flexibility for future customization, enabling adjustments to the polymer composition or connector shape based on evolving performance needs. However, the frame retained its traditional geometry and external cable routing, keeping the design simple and adaptable for practical use.

Frame 018 represented a balanced approach to material experimentation, emphasizing modesty in its ambitions while contributing valuable insights to the project’s ongoing research. By blending anatomical inspiration with modern fabrication techniques, it demonstrated how even subtle design choices can have a positive impact on ride quality. This iteration reinforced the project's focus on sustainable innovation through gradual, thoughtful advancements.

Frame 019 

"Bicycles may change, but cycling is timeless." — Zapata Espinoza 

Precision Epoxy Casting without Fiber Reinforcement

Frame 019 marked a significant evolution in the project's construction approach by eliminating the need for fiber reinforcement altogether. Instead, the frame utilized 3D-printed open-face molds filled with epoxy resin to create precise, robust joints. This method prioritized structural integrity and customization, achieved through advanced epoxy casting techniques.

A new jig system was developed specifically to support this process. The jig ensured precise alignment of the frame components and molds, stabilizing the entire setup during the epoxy casting phase. This allowed the resin to solidify into highly accurate, seamless joints, maintaining structural consistency without the complications of fiber layering.

The process began with digitally designed and parametrically modeled molds, tailored to the frame’s specifications. These molds were printed to fit over the tube junctions and were then filled with epoxy resin. Without fiber materials, the epoxy handled load-bearing and vibration-dampening tasks, offering both stiffness and flexibility where needed. The absence of fibers simplified the process while retaining performance optimization through precise material placement.

This innovation allowed for faster assembly and greater adaptability in design. Builders could quickly modify molds and jigs to explore different geometries or joint configurations, promoting a more iterative and scalable approach to frame customization.

The frame retained external cable routing, keeping the focus on enhancing joint construction and material efficiency. The exclusion of fibers demonstrated the potential for epoxy casting to independently fulfill both structural and functional requirements, streamlining the manufacturing process while maintaining high standards of durability.

Frame 019 exemplified a shift toward minimalist, precise construction methods, emphasizing small but impactful improvements in frame-building techniques. By combining custom jigs, epoxy casting, and digital fabrication, this iteration reinforced the project’s commitment to sustainable design, adaptability, and performance-driven innovation without overcomplicating material integration.

Frame 020

  "Ride as much or as little, or as long or as short as you feel. But ride." — Eddy Merckx 

Transparent Casting and Extreme Geometry

Frame 020 advanced the epoxy casting techniques explored in Frames 018 and 019, pushing the boundaries of both geometry and material aesthetics. This iteration introduced extreme frame geometries, designed to challenge conventional structural norms while maintaining precision and durability. The key innovation lay in the use of transparent epoxy, which allowed the frame's internal structure and joint composition to remain visible, offering a blend of aesthetic appeal and structural clarity.

The frame construction relied on custom 3D-printed molds, refined to accommodate the complex geometry of this design. These molds were critical in ensuring that the epoxy cured correctly within the unconventional frame angles and curves, maintaining alignment and load distribution. The new jig system, introduced in Frame 019, continued to play a crucial role, supporting the alignment and stability of both the molds and frame components during the casting process.

The transparent epoxy served a dual purpose: it provided the necessary structural reinforcement while also showcasing the frame’s unique design features. The visual transparency emphasized the precision of the casting process, drawing attention to the seamless joints and intricate tube connections. This approach highlighted the potential of epoxy casting to support both form and function, particularly in custom frame designs with complex geometries.

Without the inclusion of fiber reinforcement, the frame relied entirely on the strength and flexibility of the epoxy material. This fiber-free approach simplified construction while maintaining performance standards, reinforcing the project's focus on minimalist, adaptable manufacturing techniques. The frame design demonstrated how advanced epoxy technology could enable greater creative freedom in bicycle frame construction.

External cable routing was retained to keep the design clean and maintenance-friendly, ensuring that the focus remained on the geometry and material innovation. Frame 020 served as both a structural experiment and an artistic statement, demonstrating the potential for extreme customization through digital fabrication and epoxy casting.

This frame represented a culmination of ongoing research into epoxy-based frame design, solidifying the project's commitment to continuous material and process development. By merging cutting-edge techniques with visual transparency, Frame 020 underscored the versatility and creativity inherent in modern bicycle design, offering new possibilities for both performance enhancement and aesthetic innovation.

Frame 021

 "I like riding a bicycle built for two  by myself." — Harry S. Truman

M.O.A.B stands for Mother of All Bicycles

Frame 021, dubbed the M.O.A.B (Mother of All Bicycles), represents the culmination of the entire Frame Story project. It is the most ambitious frame developed, integrating all prior innovations with cutting-edge technology to create a highly modular, adaptable, and future-proof design. The M.O.A.B was engineered with CNC machining and laser-cut parametric parts, ensuring precision manufacturing and compatibility with evolving industry standards.

The frame is built with modular core elements, allowing users to easily swap out and upgrade key components such as the head tube, bottom bracket, and dropouts. This design enables the frame to be adjusted to different riding styles and mechanical requirements without the need for a new frame. The modularity supports both off-road and on-road applications, offering customization for various cycling disciplines such as mountain biking, touring, and commuting.

One of the key features of the M.O.A.B is the jigless system, where the frame itself serves as the alignment structure during assembly. This eliminates the need for heavy industrial jigs and reduces the carbon footprint of frame production. By relying on 3D parametric parts, the system allows for highly efficient small-batch or DIY production, enabling greater accessibility for independent builders.

The frame includes over 70 attachment points, allowing for extensive customization with accessories. These points can accommodate storage solutions, racks, bottle cages, and other components needed for long-distance cycling or utility purposes. The frame also integrates hidden internal cable routing, making it compatible with advanced electronic groupsets like Shimano Di2. Additionally, there is built-in support for a concealed electric motor, offering hybrid functionality for riders seeking both manual and assisted propulsion.

In terms of structural innovation, the M.O.A.B incorporates tension-based design principles similar to earlier frames in the project. Quick-release connectors and modular units allow the frame to be easily dismantled and reassembled, facilitating transportation and storage. This makes the frame suitable for expedition travel and disaster-area deployment, where portability and reliability are critical.

The project also envisions further developments, including a user interface for frame customization. A dedicated app and web platform are planned to enable customers to configure their frames digitally, selecting options for geometry, materials, color schemes, and accessories. This system would streamline the customization process, allowing riders to design frames tailored to their specific needs and preferences.

Another innovative feature of the M.O.A.B is the concept of a survival bike. This version would be designed to support emergency operations, potentially integrating environmental sensors and RFID technology for real-time data collection. Such a bike could serve both civilian and professional use cases, providing critical mobility and environmental awareness in disaster or remote locations.

The frame is designed to accommodate tandem configurations, with the capacity to connect up to four riders or additional cargo (including pets). This versatility makes the M.O.A.B not only a practical machine but also a statement on the potential for bicycles to serve diverse purposes in both daily life and extreme scenarios.

In terms of aesthetics, the M.O.A.B is a reflection of the project’s artistic aspirations. The frame’s clean, geometric design emphasizes minimalism, while the modular nature allows for creative personalization. Riders can express their identities through a combination of printed fabrics, anodized metal finishes, and layered fiber laminates.

The M.O.A.B represents the highest synthesis of the Frame Story project's themes: sustainability, technological innovation, and adaptability. By integrating modularity, jigless manufacturing, and digital tools, this frame offers a bold vision of what bicycles can achieve in both form and function. It is a testament to over a decade of research, development, and continuous experimentation in the field of bicycle design. This frame brings the Frame Story project full circle, pushing the boundaries of what bicycles can be while remaining grounded in the principles of local, sustainable production.

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