Astro Gravel: designed to go further
- Case Develop an all-new full carbon fiber gravel e-bike
- Client Astro Tech Co. Ltd
- Industry Mobility
How do you create a lightweight, high-performance carbon gravel e-bike that feels as agile and capable as a traditional gravel bike, while seamlessly integrating electric assistance and a distinctive new visual identity?
Working with Astro Tech, we set out to develop a frame that would balance performance, practicality and progressive design. The challenge was to integrate the Bosch SX drive system, battery and range extender into a sleek carbon frame without compromising its lightweight character or the freedom of the gravel riding experience.
At the same time, we wanted to create a distinctive visual signature. The integrated daytime running lights became a key part of the design, enhancing visibility while giving the bike a unique and recognisable identity.
Combining Astro’s deep technical knowledge with our expertise in bicycle design, we started with an in-depth research phase. Together, we analyzed rider needs, market trends, and benchmark products to define the ideal gravel e-bike geometry and hardware setup, establishing a strong foundation for the design that followed.
Modern bicycle frame design fully embraces the structural advantages and aesthetic freedom of carbon fiber. During the concept phase, we explored a wide range of design directions through a series of expressive sketches. Together with Astro, we identified the integrated lighting concept as the most distinctive and promising solution.
The final design combines strong, confident lines with a sleek and lightweight appearance. Seamlessly integrated daytime running lights create a unique visual signature, enhancing both visibility and unique identity while emphasizing the bike’s progressive character.
Using SolidWorks, the final frame geometry and hardware integration were developed into a precise engineering package, providing a solid foundation for the surface development phase.
The selected design theme was then translated into high-quality digital surfaces using Autodesk Alias. This automotive-grade surfacing process enabled meticulous control over proportions, surface transitions, highlights, and reflections, ensuring every line contributed to a refined and purposeful appearance. Ultimately, great bicycle design is not only about performance and functionality, it is also about creating a strong sense of quality and craftsmanship through every detail.
