When I joined BMC Switzerland in 2022, the brand’s integrated cockpit technology was already well established. However, it came with a limitation: fully integrated cable routing was only available on bikes starting at around €7000.
The reason was simple. The only compatible stem used for internal cable routing was the ICS2 stem system, a high-end solution whose cost made it difficult to specify on more accessible models. As a result, integrated cable routing remained restricted to the top of the range.
The high end ICS2 stem.
Together with Angelo Lecchi, also Senior Product Manager, we pushed internally to explore alternatives. We asked the R&D team to develop a more affordable solution that could bring integrated cable routing to a wider range of bikes.
An initial idea emerged: creating a more economical version of the ICS2 stem. Unfortunately, even this approach remained too expensive to reach the desired product segments.
So during the long weekend of May 1st, 2022, I started working on the problem myself.
The « Core » Idea
The concept was straightforward: use the existing BMC RSM01 stem, whose cost structure was ideal, and combine it with the ICS2 ecosystem so that existing top cones and spacers could still be used.
What was missing was the interface between the two systems: the ICS spacers and the stem.
This interface quickly became known as ICS Eco.
The BMC RSM01 stem.
Version 1 – Making It Work
The first version guided the cables under the stem while using the same upper volumes as the ICS2 system. To close the back of the stem, a cover was added behind it.
To ensure proper fixation on the fork steerer, the design reused the ICS2 stem’s wedges that press against the sides of the flat steerer tube.
The V1 concept worked, but it was visually quite large.
Initial concept mimics ICS 2 stem.
Version 2 – Reducing the Volume
About a week later, a second version appeared. The goal was to reduce the size of the rear section by finishing the RSM01 stem with a smaller appendix. This improved the proportions and reduced the visual mass.
Version 2 with the back appendix.
Version 3 – Simplifying
The third version followed immediately. It aimed to simplify the design by removing the appendix entirely. While technically simpler, the result was visually less appealing and still lacked the ICS wedges.
It was clear that the concept needed further refinement.
Version 3 with minimalist design.
Collaboration and Refinement
At this stage, I began a close and very enjoyable collaboration with Etienne Goy, the engineer responsible for the project. Together we refined the concept and worked through the technical constraints to find the right balance between cost, integration, and aesthetics.
One of the many 3D printed prototype. Here with the V4 design.
Version 4 – The Final Concept
In December 2022, the fourth version finally gave the project its definitive direction.
This iteration:
Integrated the ICS wedges to press securely on the sides of the fork steerer
Allowed the addition of a clip-on finishing cover for the rear of the RSM01 stem
Preserved compatibility with the existing ICS2 spacer and top cone ecosystem
The result was a clean, efficient, and cost-optimized interface.
Version 4 featuring the final shapes and elements.
From Prototype to Production
With the concept validated, the project entered full development. The first production parts arrived shortly afterward and began appearing on many models of the 2024 range.
ICS Eco ultimately achieved its objective: bringing the visual cleanliness and functional benefits of integrated cable routing to bikes at retail price starting from €2500.
A Project I’m Proud Of
From the initial need to a working prototype and finally to a production solution perfectly aligned with cost targets, ICS Eco represents the type of project I value most.
It started with a simple observation, evolved through rapid iterations, and succeeded thanks to strong collaboration between product management and engineering.
And for me personally, it remains a project I’m particularly proud of.
The MY27 Teammachine SLR ONE with the ICS Eco and RSM01 stem.
Creating a user manual might seem like a daunting task, but with the right approach, it becomes a straightforward and essential part of product development. A good user manual serves as a comprehensive guide for Riders and Retailers, ensuring they can easily understand and use your product while minimizing the need for Customer Service support. In this article, I’ll walk you through the steps involved in creating a user manual, using the some of the latest BMC frame specific manuals as an example to illustrate key points.
Step 1: Understand the Product information ecosystem and Audience
The brand’s website, its product details, and the general bicycle owner’s manual are two of the most important sources of information available. They already compile answers to address the rider’s needs. The website covers user benefits and model specifications, while the general bicycle owner’s manual covers legal obligations. We do not want to repeat the content of these two sources in our detailed technical manual unless they provide additional technical insights that address the rider’s needs.
A technical manual is essential because it provides clear, detailed instructions on how to use, maintain, and troubleshoot a product, ensuring users can operate it safely and efficiently. It helps prevent misuse, reduces customer support needs, and improves the overall user experience. By offering step-by-step guidance, a technical manual empowers users to get the most out of the product, ultimately increasing satisfaction and reducing the likelihood of mistakes or damage.
Before you even start writing your manual, it’s crucial to understand the product inside and out. A deep understanding of the product helps you highlight important features, clarify common issues, and provide the correct instructions. So grab your toolbox and start exploring all the details of your product. Your experience will ultimately make the difference.
Step 2: Outline the Structure
A user manual typically follows a specific structure to ensure that users can find the information they need quickly. The approach I’ve chosen is to follow the assembly steps. This ensures a logical flow in every step and mostly prevents missing steps when assembling complexly designed products.
Cover Page
Product name and model, Brand logo. Don’t make it to laud or complexe. This document should be timeless and always be inline with your Brand’s corporate identity.
Table of Contents
Clearly list all sections of the manual, making it easy for users to navigate. When exported as a pdf or webpage, the table of content will help you to quickly jump to a section with a click on the chapter.
Introduction and Technical Specifications
A brief overview of the product, Intended use and target audience, Safety precautions or warnings. Repeating some of the key safety elements is useful. In some case, it’s exeptionaly repeating content already published on the website or General owner’s manual.
Assembly Instructions
Step-by-step instructions on how to assemble the product. Includes as many visual aids (diagrams, images). This includes adjusting settings, operating the product, and maintenance tasks.
Maintenance & Troubleshooting
Regular care tips and instructions on how to maintain the product.
Common issues and solutions (e.g., how to clean the bicycle, adjust brakes, etc.).
Warranty and Support
Provide warranty details and instructions for obtaining customer support if issues arise.
Step 3: Write Clear and Concise Instructions
One of the most important aspects of a user manual is clarity. Instructions should be simple and direct, especially when dealing with complex products.
For example, in most manuals I’ve created, the instructions are laid out step-by-step with images and diagrams that accompany the text. This makes the manual easy to follow and ensures that users don’t miss any crucial steps during assembly or setup.
Text is not ideal. It must be written in a chosen language, which can make it difficult to access if not translated into local languages. Try to stick to the point and minimize it. The ultimate goal is to create a mostly visual manual, similar to LEGO or IKEA instructions. However, this is particularly challenging for a bike manual.
This is even more true when highlighting critical notes. Warnings and information blocks must be clearly identified to warn riders about key details.
Avoid jargon unless necessary, and if you need to use technical terms, make sure to define them. The goal is to make the manual as user-friendly as possible, regardless of the reader’s technical background.
Step 4: Use Visuals to Support the Text
Visuals can make or break a user manual. Diagrams, images, and screenshots are invaluable for clarifying complex instructions.
Use high-quality images that are easy to interpret. You may also want to include icons or symbols to represent warnings, tips, and other critical notes, making it easier for users to spot important information at a glance.
Clear 3D illustrations are a must. This help to show on a flat surface (screen or paper) what the Rider sees. Design 3D softwares are enabeling a lot of possibilities to generate a clean document showing details without the background of a photo or the lack of details or perspective of a sketch.
On the top of 3D rendering, make sure you are adding clear icons or symbols and info to instruct the operation details. Arrows, info box and color highlights are a must. And talking about icons and colors, using a convention as universal as possible will facilitate the understanding for your Rider. Great conventions are already in use by SHIMANO and SRAM in their manuals. Do not copy but don’t go too far from what they have established.
Step 5: Test the Manual
Once the manual is written, it’s essential to test it. Testers are of many types.
Engineers: At the heart of each component design, the engineer will help verify if all parts are illustrated correctly and if all technical details are clearly defined and explained.
Quality Managers: With a strong focus on troubleshooting and extensive experience in customer service support, quality managers will definitely assist with legal and critical sections. In addition to content, they will often help integrate the document into the company’s document management system for future traceability.
Graphic Designers: A document is only valuable if it’s visually appealing and easy to read and understand. Graphic design and layout must be spot-on.
Product Managers: With a different perspective than engineers, quality managers, or graphic designers, the product manager will approach the document with a broader view.
Ideally, once experts have covered their areas, have someone unfamiliar with the product go through the manual and attempt to use or assemble the product based on your instructions. This will help identify areas that might be unclear or incomplete., the Product Manager will be looking at the document with a wider approach.
Step 6: Update and Maintain the Manual
Product updates, and new features may require periodic updates to your manual. Make sure to keep the manual current and relevant by incorporating any changes or improvements that arise after the product is released.
Track Versions: Clearly identifying the version of your document is crucial for effective communication with riders.
A manual may need updates based on user feedback, new bike accessories, or new maintenance tips that are introduced after the product launch.
Conclusion
Creating a user manual requires careful planning, clear writing, and a good understanding of both your product and your audience. By following the steps outlined above, you can create a comprehensive and user-friendly manual that will enhance the customer experience and reduce the need for customer support.
Whether you’re on a bicycle project or developing another type of product, following these steps will ensure your manual meets your customers’ needs and helps them get the most out of your product.
References
Looking back, I’m grateful for the opportunity to have contributed to these owner’s manuals that I’m proud to have worked on.
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GIANT 2010 TRINITY ADVANCED SL instruction manual
GIANT 2011 TCX ADVANCED SL instruction manual
BMC ROADMACHINE Gen3 Owners Manual (2023)
BMC SPEEDMACHINE Gen1 Owners Manual and Sizing Guide (2023)
Shine Bright! I bought a Varia almost a year ago, but I wasn’t a fan of the elastic straps used to secure the bulky mount to the seat post. So, I designed a custom 3D-printed holder that fits perfectly with the original Garmin interface — or the Mr. Control Garmin adapter I had lying around in my spare parts bin. The design is tailored to fit the back of the 10mm offset BMC Teammachine SLR seatpost. The lower bolt tightens against the saddle clamp hardware, ensuring a secure and stable attachment.
I printed the part using PLA on my trusty Creality Ender 3. The hardware shown is temporary, as I plan to upgrade to sleek stainless steel bolts and nuts, replacing the standard ones pictured here.
The final version assembled on the seatpost and its design in the background.3D assembly in OneShapeSub-assembly showing the Garmin Varia interface fitted into the 3D printed partMr Control interface versionGarmi Varia interface version
Riding without a tool isn’t an option for me… and forgetting to bring one is definitely something I want to avoid. Riding with pockets full of gear isn’t very pleasant either. So, reusing a Specialized SWAT Road tool and designing a tool holder that attaches under the bottle cage specific to the BMC Teammachine SLR was a cool project to work on.
The tool holder at the bottom of the SLR bottle cage
Tool in grey fitted into the holder
Detail of the ramps holding the tool in place
Final print on the bike with the tool
Tool out
Tool in
The tool holder clips securely at the back of the bottle, preventing it from moving or vibrating. A small fixing tab slides under the bottle cage and attaches to the lower bolt, sandwiching the whole setup in place. The tool is inserted into the holder from below, so you don’t need to remove the bottle to access it. The tool’s outer shape locks into the ramps of the holder, keeping it securely in place during the ride. The top face of the holder acts like a spring clip to hold the tool in position.
The attachment is solid, the tool stays in place, and the aesthetics are still as sharp as ever on the Teammachine SLR handlebars.
I have not shared this design as it’s quite specific to my own needs. Feel free to reach out if you need help.
