Critical screws: an overlooked component in bicycle manufacturing
BMC Switzerland may not yet be one of the big bicycle manufacturers. But that is what makes the BMC Bicycle Manufacturing Company strong. A small customer-oriented company with its headquarters in Grenchen, Switzerland, whose goal is to bring joy with high-quality bicycles - from children's bikes to downhill machines. BMC stands for Swiss quality, which the company demonstrated with strong performances of the racing team in the Tour de France, becoming a world-renowned bicycle manufacturer.
The high demand for quality and precision is already evident when Development Manager Stefan Christ speaks about the diverse challenges in producing a bicycle: "Screws are often the components that are a hard nut for us. Whether screws or other connecting elements, they are critical points in the structure of the bicycle and can greatly affect the safety when riding," says Stefan Christ. "In internal and external stress tests, it's often the screws that don't withstand the extreme stress," he explains. Not because they are of poor quality, but because this important element often receives too little attention.
Engineering aesthetics and durability
Another focus of the high-tech bicycle manufacturer is on design. A BMC bike should stand out from the crowd even without color and logos. This requirement presents another challenge for the engineers who are searching for the ideal fastening solution. Typically, the screws must be coated black so that they match the unified quality look and feel of BMC. Additionally, the wheels must withstand the harshest requirements in standardized stress tests in terms of vibration and corrosion. Only when the lightest screw with the best cost-performance ratio is found, the solution will be ideal.
Development of a specialized bolt
Bossard has developed ecosyn®-grip, a specialized bolt, that meets both client-specific requirements and the standard regulations of EN14766 for mountain bikes. EN14766 is a comprehensive set of safety regulations for bikes and the accompanying test methods to ensure the quality and performance of a bike. The standard requires that the handlebar and stem must endure 200,000 cycles during an endurance test, making it a stringent test of the materials and components used in a bike. In response, Bossard conducted a thorough analysis of the existing design and various tests to evaluate the mechanical properties and behavior under vibration.
Meeting highest industry standards
ecosyn®-grip meets the high demands of the bicycle industry for quality, precision and safety. This new bolt from Bossard is a testament to their commitment to providing reliable and high-performing products for the industry. The client's interest in the performance of the newly developed bolt led to an extensive endurance test. Over the course of a month, the bolt was subjected to over 4,000,000 pedal turns under high vibrations and harsh environmental conditions to gauge its quality and performance.
Enhanced safety and productivity
The results of the tests were overwhelmingly positive and confirmed the high quality of the bolt. To ensure the accuracy of the results, the tests were not only conducted in the company's own laboratory but also independently certified by SGS, an external laboratory. In addition, the design of the bolt was further improved by replacing the washer with a scalloped edge on the bolt head, reducing the risk of loss. This design change also resulted in fewer fasteners and washers being required during the assembly process, increasing productivity and reducing material costs. Most importantly, the new bolt provides an increased level of safety for cyclists, and its design seamlessly integrates into the simple, clean design of the BMC bike. The development of this high-performing bolt is a testament to Bossard's commitment to producing reliable and innovative products for the industry, while also ensuring the safety of the riders.
Highlights of ecosyn®-grip at a glance
- High anti-vibration capability
- High fatigue-strength
- Economical assembly
- Savings on material costs
- Awarded with the TAIPEI CYCLE Design & Innovation-Award
Ask our Engineering Experts for advice