Mikel Arnao · Product Design Engineer
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p. 11Work 03 · Product

Cycle Dry · Orbea

A simpler, cheaper bikepacking rack with a hanger to dry clothes on the move.

My role
Led the market and usage analysis, the ideation phase (sketches developed with a teammate, except the preliminary designs), the specification document and the manufacturing process for the proposal. Led the final renders.
Year
2025
Context
Academic · PBL 3, 2nd year · reference product by Orbea
Team
Ekain Ardanza, Mikel Arnao, Leire Arias, Laura Cuesta, Naroa Galdos
Tools
SolidWorks, KeyShot, CES EduPack, Vickers and EDX testing
013D · drag to rotate

    Exploded view Simplified model of Cycle Dry · Orbea, generated in code.

    0%
    €125 → €50–60target price against the original rack
    90° / 180°the hanger lifts, then turns out of the wind
    Al 6061main alloy, identified by density, Vickers and EDX
    Final render of Cycle Dry on a hardtail MTB.
    Fig. 02Final render of Cycle Dry on a hardtail MTB.
    § 01

    Context and brief

    Orbea's MTB hardtail rack costs €124.99 and has many parts. The brief: make it simpler and cheaper for bikepacking. The user is a young cyclist on long routes who needs to wash and hang her sweaty clothes without losing them.

    § 02

    Research

    The rack was cut into nine samples and tested for density, Vickers hardness and EDX composition: mostly Al 6061, an Al 3003 mudguard, an AISI 1030 steel rod, a PET bag panel and a DLC coating. Six competitors were mapped by price and added value to find the gap.

    Moodboard.
    Fig. 03Moodboard.
    CMF moodboard.
    Fig. 04CMF moodboard.
    § 03

    Concepts

    Rotating sketches produced many redesigns. The chosen one adds a rectangular hanger on the rear bar that lifts 90° to hang clothes and turns 180° to avoid drag, or to dry them when parked.

    Concept sketch of the hanger.
    Fig. 05Concept sketch of the hanger.
    Ideation sketches.
    Fig. 06Ideation sketches.
    § 04

    Development

    The side bar between the stays was removed, since panniers now hang from the top bars, and the frame became a single bent tube plus the front and rear bars.

    CAD detail of the hinge mechanism.
    Fig. 07CAD detail of the hinge mechanism.
    § 05

    Specification

    Specification sheet for the 50 cm strut to the rear axle:

    • 20 kg without plastic deformation
    • 190 MPa tensile strength, 69 GPa Young's modulus
    • −10 °C to 50 °C operating range
    • Al 6061, 2720 kg/m³, measured hardness 93.3 HV
    § 06

    Manufacturing

    Extruded aluminium tubes, CNC bending, MIG welding and anodising for the frame. The hinge is made from extruded profiles with CNC turning and milling, drilling and tapping.

    § 07

    Result

    Render of the rack.
    Fig. 08Render of the rack.
    Final poster.
    Fig. 09Final poster.
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