Inspiration & Goal: Inspired by pro cycling aerodynamics (like the Colnago Y1rs) and seeking to enhance my Cervelo C5, I undertook the design of a custom integrated handlebar to improve performance and aesthetics.
Core Challenge: The main engineering task was overcoming the incompatibility of an integrated cockpit with the C5's standard head tube, requiring a custom integration solution.
Design & Validation (NX CAD):
Modeled the handlebar's complex aerodynamic and ergonomic surfaces using NX CAD.
Designed necessary custom spacers to bridge the interface between the integrated stem and the C5's steerer tube.
Planned critical virtual assembly in NX, including modeling the existing headset, to ensure precise fit before physical prototyping and bike modification.
Prototyping Plan: Intend to use iterative 3D printing (2-3 cycles) for physical test-fitting and refinement, ultimately targeting a final build in carbon fiber.
Learning & Outcome: This project significantly developed my advanced surfacing skills in NX and provided practical experience in component integration, virtual validation, and iterative design, merging my passion for cycling with engineering problem-solving.
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Integrated Handlebar
Project Timeline
Jul 2025 - Sep-2025
OVERVIEW
This personal project was driven by a desire to upgrade my Cervelo C5 with an aerodynamically integrated handlebar, inspired by professional cycling designs like the Colnago Y1rs. Using NX CAD, I modeled the complex handlebar surfaces and designed custom spacers to overcome the main challenge: integrating the new cockpit with the C5's existing head tube. My process prioritizes digital precision, planning a virtual assembly in NX to verify the fit with the modeled headset before proceeding to iterative 3D printing for physical testing. The ultimate goal is a final version manufactured from carbon fiber. This project significantly enhanced my advanced CAD skills and provided valuable experience in component integration and iterative design, directly applying engineering principles to my passion for cycling.
SKILLS
NX CAD ProficiencyAdvanced Surface ModelingSolid ModelingParametric Design.Component IntegrationReverse EngineeringErgonomic DesignAerodynamic Principles (Applied Design)Iterative Prototyping PlanningDesign for Manufacturing (DFM)Problem-SolvingAttention to Detail
Additional Details
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