Kanban 3 min Design 11 Sketch tapered tube profiles for top-tube / down-tube junctions Design chainstay / seatstay dropouts Define lug geometry for fork crown Model cable routing solutions (internal vs external) Design brake bridge & mounting points Develop lightweight gusset optimisations Define tolerances for all mating lug faces Iterate on seat lug airflow / aesthetics refinements Perform finite element analysis (FEA) of seat lug under load Design seat lug (completed) design reference parts from dummy bike. 3D Printing 10 Determine optimal wall thickness for strength vs weight trade-off Print test geometries for lug fillet radii Validate UV & moisture resistance of printed PA12-CF parts Test mechanical stress (bend / shear) of prototype lug Perform post-processing tests: sanding, resin infiltration, heat treatment Test layer adhesion / interlayer strength with PA12-CF Select optimal print orientation for load bearing lugs Calibrate printer for PA12-CF Validate cooling strategy for PA12-CF Print test part at 100% infill Workshop 9 Create fixture for lug alignment during brazing/gluing Setup safe clamping method for holding bamboo tubes Experiment with adhesives / bonding techniques for lug-to-tube joining Test sealing / waterproofing of joints Machining trial for metal inserts or reinforcement patches Sand, finish, and treat bamboo for durability & finish Develop & build a jig for tube mitering / cutting Develop rigs/jigs for tube diameter reduction Confirm method to reduce bamboo tube diameters Research 7 Benchmark competitor bike lug geometries and features Survey material options (e.g. resins, composites, metals) for strength/weight/cost Investigate cycling-standards / safety regulations (ISO, EN etc) relevant to frame integrity Explore new joining methods (e.g. adhesive bonding, filament winding, metal inserts) Analyse fatigue life of composite vs traditional framed parts Review heat treatment / annealing treatments for metal components Stay abreast of advances in 3D printing materials / techniques affecting bike frames Administration 6 Prepare R&D budget forecast (materials, printing, machining) Track supplier lead times and cost estimates Setup periodic review meetings / design reviews Maintain risk register (what could fail, mitigation plans) Document all design decisions & trade-offs in shared log Define version control / CAD model management process Purchase 6 Purchase fasteners & hardware matching lug designs Obtain protective coatings / sealants Order printing consumables (filament / powder / PA12-CF stock) Buy material samples (bamboo, resins, composite fabrics) Acquire test adhesives / bonding agents Source high-strength metal inserts or bushings Branding / Project Name 18 Verify trademarks / domain name availability for shortlist names Design logo, branding Create Social media accounts Design logo options & mockups Define project mission / brand identity (tone, values) Prepare website / social media name assets Seek feedback from community / potential customers on name choices OpenFrame VeloPen Layer Legion BamBikes Oh My Gear Blacksmith Wander Midride Open Craft Cycles OCC Cyclibre T800 bikes