Project N1 - nearing production, and coming in carbon fiber.
It’s been a while since our last update, and you might have wondered if we’d hit pause on Project N1. We have good news - we’ve significantly expanded its scope and are now preparing two versions for production.
What you see rendered above is the nearly finalized carbon fiber version of the metal prototypes that Randall and I have been putting through their paces over the past year. Tooling is underway, and we anticipate shipping our first batch before the start of the 2026 riding season!
So, how did we get here?
A year ago, we began design work on a unique fork to pair with the Titanium frame we had under development. Off the shelf options lacked the functionality we needed to unlock the full potential of our one-bike platform, so we set out to create one (more about this in an upcoming newsletter).
In our search for a manufacturer with the expertise necessary to produce our fork, we met with a Taiwanese factory that has been innovating in carbon fiber manufacturing since before it was being widely used in the bike space; a unique producer with deep experience in the manufacturing process, not just on tooling and layup, but also in producing their own pre-preg carbon fiber with proprietary resin systems. Importantly, with the potential for tariffs looming, they were doing all of this in Taiwan.
Raw carbon strands being spooled into alignment in our manufacturing partner's Taichung facility
Producing the fork with them was a no brainer. However, as we shared more about our research into bike fit and vision for a one-bike platform with them, an opportunity for a more ambitious collaboration emerged. Recognizing the potential of our vision for Project N1, they committed to providing engineering support and helping us offset tooling costs in exchange for us advising on other projects they were working on.
Perfectly aligned carbon being rolled into sheets with just the right amount of resin, then carefully laminated onto a backing sheet
To be frank, without this level of collaboration and support, a carbon fiber version of this bike would not have been feasible for at least a couple more years. Producing a bike frame in carbon fiber is an order of magnitude more complex and costly than metal; from the design phase all the way to production, there are cascading decisions that emerge in carbon that don’t exist when you’re just bending and welding metal tubes. The benefits, however, are immense. The design freedom and incredible material properties have enabled us to add even more off-road capability and tire clearance at road-bike weights, all while enhancing road-mode performance and aesthetics. We’re excited to integrate what we’ve learned while designing the carbon bike into the Ti version that many of you have been waiting so patiently for (thank you!).
It’s been a long road, but after many months of dialing in every single aspect of geometry, adaptability, compatibility, and usability, we’re excited to share our progress with you.
It’s been a long road, but after many months of dialing in every single aspect of geometry, adaptability, compatibility, and usability, we’re excited to share our progress with you.
Simple and efficient tube shapes
My design philosophy for our products at both Thesis and Logos can be summed up succinctly by a quote from the iconic industrial designer Dieter Rams - “Less, but better.” One bike that can be many, certainly, but also the design of that one bike removing all but the essential then optimizing it.
We sought to use simple and efficient tube shaping to minimize material, weight, stress risers, manufacturing challenges, and visual noise; to create a lithe, playful, dependable, and elegant machine that will stand the test of time.
Durable and adaptable interfaces
Carbon fiber is considerably softer than the steel and aluminum alloys used in framebuilding, so we focused a lot of effort on developing an interface for the sliding dropouts that insulates the friction from the sliders and the compression from repeated tightening of the bolts from the rest of the frame. We knew just using larger washers to distribute the loads widely across the carbon wouldn’t provide the level of protection we wanted for riders who would adjust their sliders multiple times a week for years on end. More importantly it did little to protect the slots in the frame, which we wanted to ensure remain precisely aligned and smooth in use.
We continued chewing on the idea, considering how best to protect every element of the slider system without adding excess weight, complexity, or visual distraction to the bike. While driving to visit the carbon factory with our engineering partner we considered a second solution: a custom insert that could fit into the slots of the sliders, with an additional surface extended outward in parallel to the frame.
We hashed out the pros and cons of the design later over dumplings. While it would almost completely protect the carbon from wear and tear, it doubled the tolerance stack, added a second interface to get dirty, and would need to be distractingly large if it were going to protect the trailing edge of the dropout. We kept it in mind, but continued exploring other ideas.
After further discussion with the production team at the factory we revisited a solution that had been one of the first considerations: co-molding a metal interface into the carbon.
A huge benefit of this construction method is its ability to tightly control tolerances. The plate is inserted in the molding process, then after the frame is fully cured the sliders are machined out and faced for perfect alignment.
This design also enabled us to extend a ridge of material on the trailing edge of the dropouts, providing a durable interface for the sliders to move along while being adjusted and brace against when the bike is being ridden hard.
We’re thrilled that ultimately the solution we developed will make the bike as durable, precise, and responsive as possible.
What's next?
We’re so excited by how close we are getting to bringing these bikes into the world and seeing how riders adapt them to their own needs. Stay tuned for more updates coming soon (we promise!). Next up Randall will share nitty gritty details on the specs, including tire clearance and a full geometry breakdown.
Thanks for tuning in,
Sam, Randall, and the team at Thesis and Logos