• Final iteration
    Final iteration






  • How Did We Get Here?

  • Our journey to create a bike cleat that reached our goals as well as made a strong and usable option required several iterations and multiple prints. The first print was based on our first CAD rendering. It was printed at 600% size in order to work as a proof of concept of how the mechanisms and the fitment would work in our system. This was printed out of PLA (Polylactic Acid) filament on a Replicator+ 3D printer by MakerBot. This print showed that there is a need for a guide rail in order to keep the pieces aligned when they move. This print gave us a better understanding of exactly how we wanted to implement changes in our future iterations.





  • Second Print Dissasembled
    Second Print Dissasembled
  • Based on our second CAD rendering we were able to print out in PLA (polylactic acid) filament on an Ender 3 3D printer made by Creality. This design incorporated "ears" to act as guide rails for the two connecting pieces. This was printed on a 1:1 scale allowing us to observe how the cleat will interact with the bike pedal. This model also helped us make some changes for our third iteration of the product. These included changing the material and printer as well as using negative features for spring retention instead of extrusions in the center. As well as increasing the length of the "ears" and removal of material in some spots. 

  • CAD Design 3
    CAD Design 3
  • Using our third iteration of the CAD model printing in nylon fiber with carbon fiber reinforcements on the MarkForged 2 printer by MarkForged Printing. This print was a much higher quality and provided a higher strength when compared to the PLA prints. This design incorporates internal channels for the spring and ripcord. The channels were modeled too small for the printer to accurately make space for the spring or ripcord. An increase in size had to be made in order for the printer to accurately print the appropriately sized channels. 

  • CAD Design 4
    CAD Design 4
  • 8 Different Iterations
    8 Different Iterations
  • Our final iteration of the Accessible SPD Bike Cleat was tested getting on and off of a bicycle. Our tests showed that our concept was sound and that the design itself could function how we intended it to. But due to the limited capability of 3D printed materials, we found through repeated testing that there were extreme amounts of wear and degradation of the part that cumulated in failure. In order to make a piece of hardware that would satisfy our needs as well as be safe for daily operations, the piece would need to be constructed out of metal. As you can see in our Evolution Tab we have requested machining quotes from several sources. 

  • Clipping In
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  • Clipping Out
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  • First Print
    First Print



  • Second Print Assembled
    Second Print Assembled





  • Third Print
    Third Print







  • MarkForged 2 Printer
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  • After 8 different iterations, we were able to nail down our final design. Each iteration had some changes to the design as well as changes in the printing process until the maximum amount of carbon fiber could be inserted into the part to form a rigid piece of hardware. 

This portfolio last updated: 19-Nov-2018 4:42 PM