"TETSUO’s aerodynamic extensions are designed for racing and triathlon bikes"
Our Materials Engineering laboratories perform torsion, fatigue and breaking load tests
We assess the strength, durability and safety of the TETSUO aerodynamic extensions designed for racing and triathlon bicycles via torsion, fatigue and breaking load tests.
The evolution of competitive cycling and triathlon are driving the development of components that are increasingly lighter, more efficient and aerodynamic. However, achieving high sporting performance is not enough: these items must also prove that they are capable of withstanding the demanding conditions to which they will be subjected over thousands of kilometres of competition and training.
- In this context, the TECNALIA Materials Engineering team has conducted a mechanical characterisation campaign for TETSUO, a company specialising in the sale of high-performance cycling components and distributor of aerodynamic extensions.
- These systems are designed to help cyclists and triathletes optimise their position on the bicycle, increase aerodynamic efficiency and maximise their performance in competition.
The challenge: guarantee the safety and reliability of a component subjected to high loads
Aerodynamic extensions are a critical component on racing and triathlon bikes, enabling the rider to adopt an optimised position to reduce air resistance and increase sporting performance.
However, this aerodynamic improvement means that the component must continuously support the athlete’s weight, along with vibrations, impact and repetitive stresses, which may affect the integrity of the joint and anchorage areas.
TETSUO therefore needs to verify the safety, strength and durability of its products before they are placed on the market and verify that they comply with the applicable regulations.
The solution: a mechanical testing campaign adapted to the product
To meet TETSUO’s requirements, experts at TECNALIA’s Mechanical Testing Laboratory have designed and carried out a characterisation programme based on the requirements set out in the UNE-EN ISO 4210-5:2023 standard “Cycles. Safety requirements for bicycles. Part 5: Steering test method”.
The work carried out includes:
- Torsional safety test, in accordance with Section 4.8 of the Standard.
- Fatigue test of the handlebar-stem assembly, in accordance with Section 4.9.
- Breaking load test, in accordance with the technical specifications defined by the supplier.
TECNALIA has carried out the machining and specific assembly of the unit consisting of the handlebars and the aerodynamic extension, developing a test setup that is capable of replicating the most demanding operating conditions.
In the torsional safety test, a vertical force of 300 N was applied to the extension in the position that generates the maximum torque on the clamps and fastenings, thereby enabling an assessment of the system’s ability to maintain its structural integrity under extreme conditions.
The unit was subsequently subjected to a fatigue test consisting of 100,000 cycles with a repeated load, simulating the stresses experienced by the component during continuous use on the road and in competition.
Finally, a load test to breakage was carried out to determine the structure’s ultimate behaviour and the load-bearing capacity of the anchoring systems.
Information relevant to product validation and improvement
The results obtained have provided TETSUO with objective data on the mechanical behaviour of its aerodynamic extensions, helping to validate the design, identify opportunities for improvement and demonstrate compliance with the requirements set out in the relevant regulations.
Furthermore, the campaign has assessed the product’s performance under load conditions representative of its actual use, providing added trust for distributors and end users in terms of safety, reliability and performance.
Leyner Useda, Head of the Mechanical Testing Laboratory at TECNALIA , has clarified that “experimental validation is an essential step to ensure that components designed for high-performance cycling combine lightness, functionality and safety. Through these tests, we have been able to replicate real conditions of use and provide the customer with reliable information to validate the product performance and support its market launch with increased guarantees."
TECNALIA, a technology partner for the validation of materials and components
Through our Materials Engineering laboratories, TECNALIA offers advanced testing, characterisation and validation services for materials, components and products across a wide range of industrial sectors. Our capabilities assess the mechanical behaviour of structures and systems, verify compliance with existing regulations and reduce the risks associated with new product development.
With specialist knowledge, state-of-the-art equipment and expertise in the application of international standards, we support companies in the development of safer, more reliable and more competitive solutions for their market launch.