How access to the latest digital technologies enabled design innovations that led to Paralympic cycling glory.
In 2013, a pair of serendipitous injuries led two young engineers to the Oxford Brookes University Cycling Club. Mike Booker left the rowing club, and Dan Bigham left the triathlon team. Both were studying motorsport engineering and enjoyed the parallels of cycling with engineering—optimising equipment and human performance to achieve higher performance. After graduating, the two stayed in touch, in some way or another.
The Beginning of WattShop and Early Designs
In an effort to make enough income to support his professional athletic career, Dan founded WattShop, a high-performance cycling equipment company, in 2016. He began by creating carbon fibre armrests and other parts that could be produced on a limited budget. Mike Booker, then working at a product design consultancy firm in North Wales, had begun making his own products in his spare time. After spotting a gap in the market with the idea of a light on a handlebar to replace the computer on a time trial bike, Mike created a ‘traffic light’ style display, enabling cyclists to see their power output while still viewing the road ahead.
After seeing his capability in product development and bringing products to market, Dan brought Mike on as a product designer at WattShop. Now head of innovation at the University of Sheffield AMRC Cymru, based in Broughton and part of the national High-Value Manufacturing Catapult network of research centres, Mike is still finding the time to design outside of his day job.
Advancing the Olympics with Digital Technologies
After targeting the Olympics in 2020, delayed to 2021 due to the pandemic, WattShop created the Cratus crank. Named after the Greek god of power, the idea was to create a stiffer crank with a narrow Q-factor—the distance between the outside of one crank arm and the other. The closer a cyclist's feet are in a race, the more aerodynamic they are. Digital technologies played a significant role in the design of these advanced components, allowing for optimizations that directly impacted performance.
In November 2019, after a sudden change in UCI regulations meant Dan needed to quickly redesign a state-of-the-art interface plate—in under two weeks—team partner Meggitt knew exactly who to turn to. “One of our team partners, Meggitt, are a tier two member of the AMRC,” said Dan. “When we reached out to Meggitt with this project, they went straight to the AMRC, knowing just how capable they are at executing unique manufacturing projects to a tight timescale.”
The Power of Digital Technologies in the 2021 Games
Based in a £20m state-of-the-art applied research centre in Broughton, North Wales, funded by the Welsh Government, AMRC Cymru is managed by the University of Sheffield and is a member of the High Value Manufacturing (HVM) Catapult, a consortium of leading manufacturing and process research centres backed by Innovate UK. AMRC Cymru’s capabilities include artificial intelligence and machine learning, additive layer manufacturing, robotics, virtual and augmented reality, human-assisted assembly, industrial Internet of Things (IIoT), digital twins, advanced metrology, digital simulations, as well as design and prototyping and many more.
WattShop’s Anemoi extensions, named for the Greek gods of wind, were released for 2021 and traveled to Tokyo with Team Denmark, who went on to win the silver medal in Team Pursuit. The extensions, an aerodynamic track and time trial bike accessory, put the rider in the optimal aerodynamic position for their event while retaining stiffness and handling. However, able-bodied solutions aren’t always optimal for Paralympic bikes—Mike and WattShop also did adaptive work with the Team GB Paralympics team to create bespoke components for individual athletes.
A New Era of Digital Technologies in Cycling
After the Tokyo Games, WattShop took a breath to look toward 2024. As Dan continued to balance engineering and cycling, breaking the UK Men's hour record in 2021, previously held by Sir Bradley Wiggins, and the world hour record soon after in 2022, all while using WattShop equipment, Mike looked toward the future of cycling engineering. Dan’s world record was broken by Italian cyclist Filippo Ganna in 2022, who improved on the 'best human effort' mark previously held by Chris Boardman since 1996, also using WattShop parts. As Mike recalls: “That generated a lot of interest.”
The Anemoi Mk2, a new version of the existing extension, was released last year—just in time for the 2024 Olympic Games, joining the Cratus Crank, which made its Olympic debut. In the Paris games, Australia, Belgium, Canada, Denmark, Great Britain, and the USA cycling teams, across Track and Time Trial, all used WattShop parts.
Digital Technologies Driving Olympic Glory
Dan hopes that WattShop’s work can show the impact engineering can have on sport at the highest level: “For WattShop components to pick up multiple Olympic medals and records across different nations is a dream for the WattShop team. Although for me, it was a nightmare racing against my own equipment, knowing how fast it is!”
After Australia grabbed Gold in the Men’s Team Pursuit using the Cratus Crank, and Great Britain won silver using the Anemoi Delta extensions, this put WattShop on two of the three podium slots. It also put them on the bikes behind UK records, world records, and Olympic Gold. As Mike pointed out: “There’s not much higher we can get than that.” But, with China, France, and Great Britain’s Paralympic teams all using WattShop parts, there’s still a chance for a full sweep of the podium later this month.
Conclusion: The Future of Cycling Innovation with Digital Technologies
Much like the AMRC’s philosophy that any progression in manufacturing is a progression for all, Mike has the same unbiased mindset: “The goal is to advance cycling as a sport. I want to see cyclists increase their performance, no matter who they are.”
As seen with the success at the Olympic Games, digital technologies are revolutionising cycling, making it possible for athletes to break records, achieve new heights of performance, and secure gold in competitive sports. The continuous integration of digital technologies, from advanced design to manufacturing processes, continues to propel the sport forward, ensuring every cyclist can reach their full potential.
