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Bikes & Big Ideas

Bikes & Big Ideas

Sports

Forge+Bond on Envisioning, Designing, Testing, & Refining a Carbon Fiber Wheel Design

Forge+Bond on Envisioning, Designing, Testing, & Refining a Carbon Fiber Wheel Design

2023-06-01
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Designing, prototyping, testing, and refining a carbon fiber wheel is deceptively complicated. Things like weight, stiffness, vertical compliance, and durability are the standard buzzwords for talking about a new wheelset, but how do you strike the right balance between all of them, and how do you go about validating a new design? And what how does athlete feedback factor in, especially considering that the needs of top-level pros aren’t exactly the same as those of mere mortals?


We sat down with Kell Kirby and Travis Tomczak of Forge+Bond, as well as F+B athlete Jill Kintner to talk about all of that, and along the way, we get into the differences between thermoset and thermoplastic carbon fiber, why Forge+Bond uses the latter when the vast majority of carbon wheels (and other carbon fiber bike parts in general) take the thermoset path, and a whole lot more.

TOPICS & TIMES:

  • The founding of Forge+Bond (2:29)
  • Travis’ role (3:44)
  • Kell’s intro & roll at Forge+Bond (6:10)
  • How Jill got involved (7:48)
  • The vision for Forge+Bond (9:35)
  • Why thermoplastic carbon fiber and what is thermoplastic carbon fiber? (15:58)
  • Why aren’t thermoplastics used more widely in the bike industry? (18:05)
  • Where do you start designing a wheel? (20:57)
  • Jill’s feedback and the role of athlete testing (30:39)
  • Forge+Bond’s design philosophy (35:43)
  • How to iterate on a design (39:45)
  • Learning from prototyping (42:15)
  • The current Forge+Bond product line & the recyclability of carbon fiber parts (46:33)

RELATED LINKS:

  • BLISTER+ Membership
  • BLISTER+ Real World Testimonials
  • Blister Labs
  • This Week’s Gear Giveaway
  • Blister Mountain Bike Buyer’s Guide

OUR OTHER PODCASTS

  • Off The Couch
  • GEAR:30
  • Blister Podcast
  • CRAFTED
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