Custom Sensor Mounts

In collaboration with MSAM, Gibli set out to create custom mounts printed in AlSi10Mg, to hold sensors. These sensors allow cyclists to both measure their aerodynamic drag and optimize riding position and equipment in real time to significantly improve performance. The project was initiated to enable rapid wind tunnels and track the evaluation of new configurations to advance cycling technology.

The number one factor in an athlete’s drag coefficient (CdA) is wind resistance relative to the cycler’s body position. In cycling, very small body position changes and equipment choices can cause significant drag differences, greatly affecting performance. Optimizing aerodynamics allows a rider to have immediate improvements with no extra equipment purchase requirements or added training time.

The optimized custom sensor mounts were printed using MSAM’s laser powder-bed fusion equipment, while the complete sensor package was 3D printed in-house by Gibli using the MJP (photo-curable inkjet) equipment. These techniques allowed for the custom sensor mounts to utilize additive manufacturing in advancing the aerodynamics of cycling.

(Left) Final print of mounts. (Right) Highlighted position of mount on bicycle.