Development of the Ironman racing fork continues: initial physical testing, fine-tuning details and the approaching carbon phase

Our project with Honza Tománek, a Czech Ironman and paratriathlete, is continuing and we are another step closer to the finish line. From the initial sketches and consultations, we have reached an important milestone: testing the physical prototype of the fork directly on Honza's racing handbike. What has happened so far and what lies ahead?

From digital design to the first ride

We kicked off our collaboration with a clear goal – to create a front fork precisely tailored to Honza's needs and racing style. Our colleague Šimon worked on the design, preparing several iterations during development and progressively fine-tuning the geometry, the mounting of individual components and other structural details.

Once the model had its final form, we could proceed to the production of the first physical prototype. The fork was created from several segments printed on Original Prusa FDM printers, which we subsequently glued together and applied a primer coat to so that the assembly and overall proportions could be properly evaluated.

The most important moment came when we fitted the prototype directly onto Honza's racing handbike. Most of the parameters matched very well, but testing also revealed a few details that will still require minor adjustments. And this is precisely where the power of rapid prototyping fully shows itself. Thanks to 3D printing, we can quickly modify the model, print it again and continue testing without a lengthy and costly manufacturing process.

The project is reaching its final stages

During the course of development, there was also a change within the development team. Šimon finished his time at PrusaLab and went freelance, but he continues to work with Honza and is putting the finishing touches to the model, which will be used for mould production.

The project is thus now moving into its final phase. Honza is negotiating with suppliers who will secure the production of the mould and the subsequent lamination of the final carbon fork. From the first sketches and digital models, we have got all the way to real testing on a race bike within a few months, and thanks to rapid prototyping, we were able to react flexibly to all insights from practice.

Now the final major step awaits us – the production of the mould and the carbon fork itself. We will continue to monitor and share this part of the project as well. The most interesting part is yet to come.