BMC Switzerland AG is a small customer-oriented company, with headquarters in Grenchen, Switzerland, that’s goal is to provide all cyclists with quality bikes – time-trial bikes, children’s bikes, electric bikes or downhill machines.
BMC found that the fasteners it was previously using were generally inadequate for the high demands of its bikes. BMC therefore called upon Bossard – with both companies jointly developing a new bolt with built-in safety function that considerably increased the level of safety for cyclists.
“There are multifaceted challenges when manufacturing a bike,” explains Stefan Christ, head of development. “Bolts are often the components that we find a hard nut to crack. Whether it’s bolts or other fasteners that are the critical points in the structure of the bike, they can strongly affect safety when it is being used. In internal and external stress tests, it is often the bolts that cannot withstand the extreme loads. Not because they are poor quality but because this important element is often given too little attention.”
Another focus of the high-tech bike manufacturer is on design. BMC is emphatic that its bikes should stand out from the crowd, even without company colours or logos. This requirement poses a further challenge to the engineer looking for the ideal fastening solution. Generally the bolts must be coated black to match the uniform quality look and feel of BMC. Furthermore the bikes must be able to withstand the toughest requirements relating to vibration and corrosion in various standardised stress tests.
“Not until the lightest possible bolt is found at the best price-performance ratio is the solution ideal,” says Stefan Christ.
Bossard’s Taiwanese technical center listened to all these client-specific requirements and was then able to develop a special bolt for the needs of BMC, which also met the standard regulations of EN14766 for mountain bikes.
The EN14766 standard includes safety regulations for bikes and describes the corresponding test methods. For example, the handlebar and stem must withstand 200,000 cycles during the endurance test. In addition to this, Bossard carried out a detailed analysis of the existing design, as well as various tests to evaluate the mechanical properties and behavior under vibration.
The result was the newly developed Bossard ecosyn®-grip bolt with higher anti-vibration properties and improved resistance to material fatigue. On the ecosyn®-grip the washer has been replaced by a scalloped edge on the bolt head, which helps reduce the risk of loss.
To be certain of how the Bossard ecosyn®-grip bolt would react in the most extreme conditions, Bossard carried out a test that measured the Bossard ecosyn®-grip bolt’s endurance over a whole month – with over 4,000,000 pedal turns at high vibrations and under harsh environmental conditions.
The tests not only took place in Bossard’s own laboratories but were also certified by the external independent laboratory SGS. This definitively proved the quality and performance of the newly developed fastener.
“Overall fewer fasteners and washers are required in the assembly process with the Bossard ecosyn®-grip, which increases productivity and considerably reduces material costs. The most important thing however in this is that safety of cyclists has been increased thanks to the new bolt and it is bedded unobtrusively into the simple BMC design.”
Having spent a decade in the fastener industry experiencing every facet – from steel mills, fastener manufacturers, wholesalers, distributors, as well as machinery builders and plating + coating companies, Claire has developed an in-depth knowledge of all things fasteners.
Alongside visiting numerous companies, exhibitions and conferences around the world, Claire has also interviewed high profile figures – focusing on key topics impacting the sector and making sure readers stay up to date with the latest developments within the industry.
