Ride outside the box

The list of specifications forms the basis of the product development process. It is developed together with the customer and documents all the relevant technical contents and milestones, goals and risks, department interfaces and responsibilities.

The future of mobility is in a radical upheaval and the question of where society is headed, and above all what with, concerns us just as much as the question of how the design and technology of bikes or e-bikes should cater to this new world. Because the future is created from solutions.

In order to develop the right concept for our customers, we always look at the purpose, requirements and cost target first. Then, and only then, is the frame created. For hardtails, city and trekking bikes, it’s based on frame geometry, material and drive type. For “Fullys” we also take the rear kinematics into consideration.

Once the frame geometry and kinematics are defined, it's time for the design. Initially design sketches are made until we attain the optimal form and function. Then by means of 3D models to check construction, tire clearance etc - and also the design. The earlier this happens in the process the better it is.

Once the design is in place, we begin with the CAD construction of the bike structure and attachments using Solidworks software. Then the design and material, customer expectation, technical requirements and production-related configuration is brought to life using digital and real prototypes along with 3D motion studies.

Together with our customers, we build complete close-to-series prototypes in our workshops. Then the assembly and fitting accuracy of components, cable routing, tire clearance, etc. are checked. This way, any errors can be corrected early and the potential for improvements recognised and efficiently utilized.

We carry out the final standard testing with the first models from the series production. If the test is passed, which requires a successful QC audit and another subsequent assembly workshop with our customers, the bikes enter series production and are ready to hit the market and the street.

As soon as the technical maturity of our CAD data allows it, we involve our production partners in a final stage whereby the design of the components is optimized once again for production. Then we release the production drawings and begin the tooling.

Using FEM, we analyse the behaviour of frames and components under load. This allows us to identify weak points, optimize the design and minimize the risk of component failure. This avoids costly tool changes and speeds up the development process.

High-end is actually simple: when you take the best of everything. The best material, highly motivated colleagues, the best tools. We know ourselves that this ideal state is not standard practice but we work damn hard every day to create such conditions.

As soon as the development has progressed in-house, we request the various parts from our suppliers. Thanks to many years of experience and extensive contacts, when it comes to imports from Asia, we can reliably handle the entire transport process.

Which material for which component – this is determined together with our production partners. Our long- term partnerships ensure process reliability and material quality. We closely monitor new material trends and analyse them for their suitability in future series production.

We consider the bicycle to be the best solution when it comes to individual mobility and the e-bike is currently the smartest development on the market. Simply due to the fact that a 100 km range from a 4 kg battery beats a 500 km range from a 700 kg battery. And because e-bikers always smile - that motivates us.

This is where our construction designs are put through their paces and test assemblies are carried out before frames go into production. For example, to find out whether a complete bike can be built with reasonable effort - and how locks, child seats and other accessories can be fitted.

After more than 30 years in the bicycle industry we know globalization is a good thing and in Asia you get fantastic production and great quality at correct prices. We have found good and reliable business partners there and even better friends. And something else that has become rare: real entrepreneurial spirit and the will to make the impossible possible.

With the development from bike to e-bike, there are entirely different requirements to be able to manufacture products completely in Europe once again. However, we at Velobyrd want to realize this “new European production” together with our partners from Asia. Because globalization doesn't stop here - it just changes direction.

Looking back, we have always learned that the best lessons are made from mistakes and setbacks. Especially in development, mistakes are crucial points – in both a positive and negative sense. That's why we encourage criticism and boldness, perseverance and openness. How else can a good team become a better one?

What used to be messy is now greener and better: our bikes are manufactured using modern methods that reduce the environmental impact to a minimum. This encompasses processes such as hydroforming, gravity casting, laser cutting, 3D printing or robot welding. Everything that makes building bikes better.

Velobyrd has set out to bring visionaries and bike freaks, craftsmen and technicians together. So combined, they can invent good things, discard them, and then create even better ones. Velobyrd is our answer to meet the increased demands of the market while utilizing new technical possibilities - and it is our responsibility to make the most of it.