AeroBarz
Parametric Time Trial Extension Bars
AeroBarz are a fully customizable time trial extension bars, designed in Rhino-Grasshopper, optimizing aerodynamics, comfort, and performance through parametric design.
Course
Design for advanced production methods & environments
Tools
Rhino-Grasshopper
Project Type
Individual academic project
Date
october 2024 - january 2025
CONTEXT
A time trial is one of the most demanding cycling disciplines, where aerodynamics and ergonomics are key to performance. Despite this:
Current Problem: Many riders still use standard time trial handlebars that don’t fit their unique physique or riding style, reducing efficiency and comfort.
Cost of Custom Solutions: Customized handlebars are expensive, ranging from €2000 to €4000.
This project, developed as part of the Design for Advanced Production Methods and Environments course, focuses on creating:
Parametric Design: Time trial extension bars customizable via Rhino-Grasshopper scripting.
Personalized Fit: Adjustments based on individual dimensions and preferences.
Cost-Effective Production: 3D metal printing reduces production costs, making it an accessible option for cyclists and triathletes.
PROBLEM
Current time trial extension bars offer limited personalization and typically fall into two categories:
Standard but Inflexible: Low-cost options that lack customization.
Custom but Expensive: High-end models with limited sizing (S, M, L) or fully customized options with high prices and long lead times.
Getting a perfect fit often requires in-person measurements at a company or waiting for a specialist, making customization inaccessible for many riders. This lack of an affordable, fully personalized solution limits both comfort and performance.
Solution Development
Parametric design enables precise adjustments to create the ideal handlebar shape.
Full Customization: Key parameters, such as armrest positioning, hand support angles, and padding thickness, are fully adjustable to match the rider’s physique and preferences.
Personalized Aesthetics: Riders can select padding thickness, color, and finish for a tailored setup.
These inputs feed into a Grasshopper script, which builds the model:
A base framework (skeleton) is generated.
Arcs for armrests and hand supports are positioned.
A loft function creates smooth surfaces between components.
The spacer and handgrip are constructed and a thickness is assigned for production readiness.
A Human UI (User Interface) is integrated, allowing users to customize their handlebars themselves using intuitive sliders and radio buttons.
OUTCOME
Users can design their own AeroBarz through the BarzBuilder user interface.
Seamless Export: The final design generates two STL files, ready for 3D metal printing.
High-Performance Material: Printed in AlSi10Mg aluminum alloy, ensuring strength, durability, and low weight—perfect for cycling applications.
Cost Reduction: Estimated production cost is €1500, significantly lower than existing customizable time trial handlebars.
