Cases / Mobility / Kú Cycle
Case · Mobility · We think in molds
An injection-molded Bento box that belongs with the aerodynamics of a racing bike
Kú Cycle builds high-performance triathlon bikes where every detail is designed for aerodynamics. For the TF1, QDP developed and produces the Bento box: the storage box on the top tube where the athlete grabs their energy bars, in full race effort.
Kú Cycle designs and builds custom triathlon bikes, with a frame that is aerodynamically optimized for each rider.
For a bike where every shape is defined by wind tunnel philosophy, a storage box can’t be a separate accessory. The Bento box had to fit seamlessly onto the frame, be lightweight, withstand sweat, sun and vibrations, and be opened one-handed while the athlete continues to pedal in aero position. Exactly the sort of small, demanding plastic product where injection molding and Design for Manufacturability come together.
The challenge
A storage box that follows aerodynamics, doesn’t disturb it
The Bento box sits on the top tube, directly behind the water bottle, right in the airflow. The exterior shape was thus largely set: it had to follow the frame. Within that shape, a thin-walled, lightweight housing had to be made that is stiff enough to be opened and closed thousands of times during the race.
These types of organic, curved shapes are exactly what injection molding calls for: draft angles, parting lines and undercuts determine whether the design is manufacturable. We contributed our mold thinking from the very first sketch, so the designer’s form would also become the form out of the machine.
Our approach
We think in molds.
From DfM check and mold flow analysis to mold building and in-house series production. The Bento box has been tested on the bike, further developed and brought into production. We are now working on the Bento box 2.0, and also produce other injection-molded parts for Kú Cycle, like levers and holders.
The result
From test day to global race practice
The Bento box is in series production and rides on TF1s in international triathlons, from training laps in the Netherlands to professional T100 races. The success of the first generation led to a follow-up assignment: the Bento box 2.0, again with DfM, mold-flow and a proprietary mold with certificate of ownership for the client.
- Aerodynamic shape retained: the box follows the frame, no concessions to the design
- In series production at QDP, from mold to delivery
- Further development to 2.0 based on race practice
- Expanded to multiple injection-molded parts for the same bike
On the move
Kú Cycle on the collaboration
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