Australian track cyclists won impressive victories at the 1995, '96 and '97 World Track Championships and the 15th Commonwealth Games. The Australian team used with stunning effect a unique carbon fibre monocoque bicycle designed and built by a project team from the Royal Melbourne Institute of Technology (RMIT University) and the Australian Institute of Sport (AIS). Developed in consultation with Charlie Walsh, the national track cycling coach, this new bicycle, the 'AIS/RMIT Superbike', has allowed the Australian riders like Shane Kelly to set new records. Continued development has resulted in over twelve World Championship titles and four world records. Including the World record for the kilometre Individual Time Trial set by Shane Kelly in 1995. The development and application of new wind tunnel testing techniques have resulted in a fifteen per cent reduction in power over the traditional diamond frame. Extensive use of a water tunnel and wind tunnel have enabled the team to optimise the frame profile for minimum aerodynamic interference from the rider's leg motion. Structural design loads were derived from track testing with strain gauged frames. Finite element analysis techniques were validated through extensive material testing. Throughout the development program extensive use was made of validated performance simulation. The simulation provided evaluation of stiffness, aerodynamics and weight. These simulations enabled rapid assessment of concepts. Track testing with power meters and strain gauged frames were used to refine design data and wind tunnel test techniques. In order to produce the resulting bicycle new manufacturing techniques had to be developed. Unlike most equipment used by elite athletes the AIS/RMIT 'Superbike' has been designed for low cost, high volume manufacture. The hollow frame is moulded as a single unit in a one shot process suitable for automation. The frame was designed to accept standard group sets and wheels. The AIS and RMIT University has lodged patents on the unique features of the manufacturing process. Bicycle Technologies Pty Ltd (Australia) has commenced commercial manufacture of track and road variants. The New Zealand National Track Cycling Team has selected the 'Superbike' for the 1997 and 1999 seasons. It is anticipated that the technology will enable a new manufacturing industry to be developed in Australia. The engineering development has resulted in the project winning an Engineering Excellence Award from the Institution of Engineers Australia, two Innovation Awards and the 1995 Velo News Award for "Best Technical Development for 1995 in Road or Track". This paper discuses the engineering techniques, research and project management required to create the Australian Superbike.
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