Zen TK001
In December 2003, work began on the production of a new composite track bike for Sarah Ulmer, New Zealand’s top female track 
cyclist. Sarah would be competing at the World Championships in Melbourne and the Athens Olympics in 2004.
Sarah had been riding what was regarded as the current world standard track bike, however it was felt that significant improvements could be made.
The project was approached and based around the principle of improvement in every area of design, material utilisation and production. A primary objective was to reduce drag and weight with no loss of power or efficiency. A wind tunnel test program was conducted at the University of Canterbury to test the frame design and drag characteristics. Further ‘live’ testing was required to gain an understanding of the critical loads and pressures placed on the bike during use. 
This involved live load testing on the track using strategically placed strain gauges on the frame, handlebars and the special construction of a force balance pedal. Data was recorded remotely and analysed post testing. The testing phase was critical in the collection of very accurate data that would act as a base for the engineering of the new frame and specifically the carbon epoxy laminate.
The frame geometry was finalised early in the project, the focus being one of minimalising weight and aerodynamic drag without compromising function.
The materials used for manufacturing the frame were sourced internationally, and the manufacturing process employed successful techniques developed from previous bike frame production.
Final results showed a bike of significantly higher standard than anything currently being produced for the market, it outperformed Sarah’s current bike in all areas.
Sarah rode the bike with incredible results. Riding the Zen ‘prototype’ at the World Champs in Melbourne, she broke the world record. At the Athens Olympics later in the year, she took the gold medal in the women’s 3000m Individual Pursuit in a time six seconds faster than the 2000 Olympics.
In the frame, fork and handlebars, the weight has been reduced by 29%, while the frame stiffness has been increased by 30%.
These results speak for themselves, in a sport dominated by substantial research and development budgets, Dynamic Composites have turned the cycling world on its head with the new design.
