None other than Marcel Kittel's race bike at rest in the lobby.

None other than Marcel Kittel's race bike at rest in the lobby (click to enlarge).​

RoadBikeReview was recently invited to the Felt Bicycles World Headquarters in Irvine, CA for the introduction of their 2016 bicycle line as well as a tour of their R&D, design, engineering and testing facility. With such deep roots in aerodynamics, racing and tri/tt bikes, it was a treat to see how these bikes come to life.

As we entered the facility, the lobby is strewn with autographed jerseys from the many champions that have ridden Felt bikes.

Our tour guide was Senior Design Engineer, Jeff Soucek who took us into the first office where computer aided design is used to draw up the preliminary designs. These designs are then tested using CFD (Computational Fluid Dynamics) and FEA testing software.

Jeff Soucek, Senior Design Engineer (standing) shows us how computers are used for design and analysis.

Jeff Soucek, Senior Design Engineer (standing) shows us how computers are used for design and analysis (click to enlarge).​

From here, we continued into another room that lead to two more engineering workstations for even further (and more complex) testing and analysis. Continuing on, we were lead to a larger room that included a pretty massive 3D printer and several tables with jigs set-up for assembling test parts and then putting them through their paces.

The jig is made to hold many different shaped parts and frames.

The jig is made to hold many different shaped parts and frames (click to enlarge).​

As massive as this 3D printer is, it can't make a full size bike frame.

As massive as this 3D printer is, it can't make a full size bike frame (click to enlarge).​

Since the 3D printer can only make pieces that are so big, complete frames are made out of several smaller pieces that are then put together. Of course, things like structural strength can not be tested on these mock-up frames, but it gives a good idea about bike shape and layout and helps with such things like water bottle boss placement and geometry.

Shown here is an example of a 3D printed frame that has been assembled.

Shown here is an example of a 3D printed frame that has been assembled (click to enlarge).​

Continue to page 2 for more Felt World Headquarters tour photos including the testing, carbon layup and more »



A 20 pound weight is dropped from varying heights to emulate impacts.

A 20 pound weight is dropped from varying heights to emulate impacts (click to enlarge).​

One of the highlights of our tour was the fork drop test machine. Basically a rig that holds forks while a 20 lbs weight is dropped on them from varying heights. Soucek stressed that Felt always tests 20% over what the industry standard requires, to insure that their parts will stand up to the abuse. Like any smart manufacturer, they also buy frames from their competition and test those, too. The fork shown here survived almost a dozen impacts from the plus 20% height before it broke. It's required to survive only one impact.

3D printing has revolutionized the design and testing world across many industries.

3D printing has revolutionized the design and testing world across many industries (click to enlarge).​

The next room we were shown had carbon frames being hand laid using Felt's InsideOut technology. This includes using a mold of pliable (but solid) material that is then expanded from the inside to create the carbon frames.

hand laid carbon mold for carbon frames

This room also included a custom brake caliper testing device that was hand built by one of the Felt engineers. This machine uses a hydraulic actuator to engage the caliper brakes over and over (100,000 cycles and more, to be exact).

This machine was custom made by one of Felt's engineers and can run over 100,000 test cycles.

This machine was custom made by one of Felt's engineers and can run over 100,000 test cycles (click to enlarge).​

Lastly, we were shown a huge CNC mill for building parts and frames on demand. Previously, Felt had to outsource their CNC jobs which would put them at the mercy (and deadline) of the machine shop. Now, with their own CNC machine, they can make parts like suspension linkages on the spot.

With their own CNC machine, Felt engineers can make parts on the spot.

With their own CNC machine, Felt engineers can make parts on the spot (click to enlarge).​

A close-up of the CNC'd linkages used on Felt's full suspension mountain bikes.

A close-up of the CNC'd linkages used on Felt's full suspension mountain bikes (click to enlarge).​

After seeing the inner workings of Felt Bicycles, it is obvious that they take their research and development seriously. They have to. When going up against bigger companies like Trek, Specialized and Giant, they have to have innovative products that work or else they won't last long. Combine all this with real world testing with elite professionals, world champions and Olympic champions and Felt's dedication and passion to improving the cycling experience for every one becomes evident.

Continue to page 3 to see highlights from Felt's 2016 road bike models like the IA FRD, AR FRD, F1 and F1x and more »



The IA FRD stands as the pinnacle of Felt's technology and design.

The IA FRD stands as the pinnacle of Felt's technology and design (click to enlarge).​

Felt IA FRD ultimate TT bike

We got the lowdown about Felt's model year 2016 road lineup from Dave Koessel, Felt Product Manager and he started off with Felt's forte - aero road bikes. He explained that current frame shapes and layups are constantly developed and optimized for their new bikes. They receive plenty of input and help from their racers like Daniel Holloway (US National Criterium Champion) and many others.

Koessel pointed out many key features of their aero bikes that they developed like the airfoil section of the headtube, designed to be it's own foil. The seatstays lack of rear brake (located under chainstays) for better aerodynamics (less drag). Felt's unique seatpost design that uses two plates drawn thin to remove harshness for the rider with an internal clamping device. This design allows for about 3mm of deflection (and thus, comfort).

The IA FRD stands as the pinnacle of Felt's technology and design. It's frame features Felt's integrated Aero Tri UHC Ultimate + TeXtreme® carbon fiber MMC (Modular Monocoque Construction) with InsideOut construction. It has a fully integrated proprietary braking system and internal cable routing that is mechanical and electronic compatible.

It comes spec'ed with Shimano Di2 11-speed drivetrain and has high tech features built in like Felt's Vibration Reducing Aero Tri UHC Ultimate + TexTreme carbon fiber seatpost that you can actually squish laterally with your hands. The cranks are Rotor Flow Aeros already equipped with a power meter. Wheels are Zipp 404 Firestrikes.

The IA FRD is available in 5 sizes (48, 51, 54, 56, 58cm) and has a claimed weight of 18.45 lbs. This bike has an MSRP of $16,999 and will be available in August of this year.

The AR FRD is the top of the line aero road bike from Felt and it has a claimed weight of 15.19 lbs and will be available in September of this year.

The AR FRD is the top of the line aero road bike from Felt and it has a claimed weight of 15.19 lbs and will be available in September of this year (click to enlarge).​

Felt AR FRD aero road

The AR FRD is the top of the line of the Felt's aero road line but if you are on a budget, there are 4 other carbon models below it. It's frame features Felt's UHC Ultimate + TeXtreme® carbon fiber MMC with InsideOut construction. It has electronic specific internal cable routing and is paired with Felt's monocoque UHC Ultimate + TeXtreme carbon fiber.

It comes spec'ed with Shimano Di2 11-speed drivetrain. The cranks are Dura-Ace with Pioneer Dual Leg Crank power meter already equipped. Wheels are Zipp 404 Firestrikes.

The AR FRD is available in 6 sizes (48, 51, 54, 56, 58, 61cm) and has a claimed weight of 15.19 lbs. This bike has an MSRP of $12,499 and will be available in September of this year.

Felt's Thomas Skujins won a stage of the Tour of California this year on his Felt F series.

Felt's Thomas Skujins won a stage of the Tour of California this year on his Felt F series (click to enlarge).​

Felt F1 traditional, lightweight racer

The F series are the lightweight, traditional racing bike line. Felt's Thomas Skujins won a stage of the Tour of California this year on his Felt F series (the only non-Specialized stage winner). The F1 is just below the top of the line F1 PR but above the F2, F3 and F4. There are also 2 alloy models. The frame is Felt's UHC Ultimate + TeXtreme carbon fiber with MMC InsideOUt construction. It has BB30 and 7075 CNC aluminum replaceable rear derailleur hanger and internal cable routing for mechanical and electronic shifting.

It comes spec'ed with Shimano Dura-Ace 2x11 drivetrain with Dura-Ace caliper brakes. Wheels are Fulcrum Racing Zero carbon clinchers.

The F1 is available in 6 sizes (48, 51, 54, 56, 58, 61cm) and has a claimed weight of 14.70 lbs. This bike has an MSRP of $6,999 and will be available in August of this year.

Felt claims that there is currently over 50% adoption of disc brakes in pro CX peleton.

Felt claims that there is currently over 50% adoption of disc brakes in pro CX peleton (click to enlarge).​

Felt F1x Cx1 cross racer with disc brakes

The F1x Cx1 is the top of the line, non-electronic shift cyclocross race bike. There is a Di2 version available as well as 2 less expensive carbon versions and 3 alloy version. It features 15x100mm maxle dropouts in the front and 12x142mm axle spacing in the rear. It's frame features Felt's UHC Ultimate + TeXtreme® carbon fiber MMC with InsideOut construction.

It comes spec'ed with SRAM Force Cx1 disc brakes and SRAM Force Cx1 cranks and 1x11 drivetrain. Wheels are DT Swiss R24s. The brakes are post mount style. Felt claims that there is currently over 50% adoption of disc brakes in pro CX peleton. For this bike, Rotor did a narrow wide ring, both included(Q and non-Q). Shifter buttons are on the right and left, with the buttons separated to right (harder to pedal) to left (easier to pedal). There is increased spring tension to help hold chain on. Felt considers this the lightest cross frame on the market at 1200 grams.

The F1x Cx1 is available in 6 sizes (47, 50, 53, 55, 57, 60cm) and has a claimed weight of 17.28 lbs.
This bike has an MSRP of $6,999 and will be available in September of this year.

Continue to page 4 to see highlights like the Z2 Disc, ZW4 womens, F24x kids and complete photo gallery »



The primary goal is not stiffness to weight(like the AR or F series), but rather comfort and ride quality.

The primary goal of the Z series is not stiffness to weight(like the AR or F series), but rather comfort and ride quality (click to enlarge).​

Felt Z2 disc comfort/endurance

The Z2 Disc is the top of the line endurance road bike, built for comfort and long rides on your adventures. The primary goal is not stiffness to weight(like the AR or F series), but rather comfort and ride quality. The Z2 Disc is the top of the line model and there are 5 less expensive carbon version and 5 alloy versions as well. The frame is FElt's UHC Performance carbon fiber with MMC InsideOUt construction. It has BB30 and carbon dropouts, IS disc mount and internal cable routing for mechanical and electronic shifting. There are disc and rim brake options through the model line.

It comes spec'ed with Shimano Ultegra Di2 2x11 drivetrain with Shimano R785 hydraulic disc brakes. Wheels are DT Swiss RC28s.

The Z2 Disc is available in 5 sizes (51, 54, 56, 58, 61cm) and has a claimed weight of 17.28 lbs. This bike has an MSRP of $5,999 and will be available in September of this year.

The ZW series has been designed with lower frame weights, lower stiffness and more vertical compliance to fit a smaller rider.

The ZW series has been designed with lower frame weights, lower stiffness and more vertical compliance to fit a smaller rider (click to enlarge).​

Felt ZW4 Disc women's bike

The ZW4 Disc is a women's specific road bike with disc brakes. They have been designed with lower frame weights, lower stiffness and more vertical compliance to fit a smaller rider. The ZW4 stands right in the middle of the carbon line-up and there are also 3 alloy versions. The frame is Felt's UHC Performance carbon fiber with MMC InsideOUt construction. It has BB30 and carbon dropouts, replaceable rear derailleur hanger and internal cable routing for mechanical and electronic shifting.

It comes spec'ed with Shimano 105 11-speed drivetrain and TRP HyRd disc brakes. Wheels are Fulcrum Racing Sport Disc clinchers.

The ZW4 Disc is available in 4 sizes (petite (43), small (45), medium (47), tall (50)) and has a claimed weight of 18.74 lbs. This bike has an MSRP of $2,799 and will be available in September of this year.

A race worthy rig ready for your budding star's miles of smiles.

A race worthy rig ready for your budding star's miles of smiles (click to enlarge).​

Felt F24x kid's cross bike

The F24x is a serious cross machine for your budding racer. It has a custom butted 6061 aluminum tig-welded frame with a threaded BB and replaceable rear derailleur hanger. It features a 2x9 drivetrain with mini V-brakes for stopping duties. Best of all, cowbell is included!

The frame is 39cm and has a claimed weight of 20.9 lbs. The F24x has an MSRP of $849 and is in stock now at your local Felt dealer.

For more information visit www.feltbicycles.com.