cycling industrial design

new product development

design process management

20 years helping visualize the future of cycling.

Hundreds of functionally, aesthetically, and commercially successful products.

Passionate about advancing the state of the cycling art, balancing creative innovation with real world experience.

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29 years of new product development.  23 years consulting, 6 years in-house.  Specialization in carbon fiber frame design and 3D CAD sculpting.

Stephens designed frames have raced in Kona, Moab, and on the Champs-Élysées with podium finishes on the WorldTour, World Enduro Series, and others.

Arevo Abu Dhabi.jpg

Frame Design

Primary specialty - sculpting carbon fiber with automotive surfacing software.  Shaped one of the first hydroformed aluminum frames in the industry with Electra in 2004.  Experience in steel, titanium, and thixoformed magnesium.  Road, MTB, TT / triathlon, urban, cyclocross, gravel, & electric.

Components & Accessories

Experience designing products across the cycling industry - components, computers, headlights, helmets, bottles, cages, crankarms, trainers,

indoor cycles, tools, scales, pumps, dropouts, chainrings, fenders, aero bars, cargo boxes, spin bikes, taillights, packs, racks, hubs, saddles...


Personally designed products for over 150 brands.  Product design, project management, and liaison to engineering and manufacture.  Product development workflows for multidisciplinary teams involving market & product research, design resources, various engineering disciplines, rapid prototyping, and design for manufacture.


Fluent in advanced surface modeling and concept visualization in 2D and 3D.  Expertise in class-A surfacing with Alias Studio; experience blending sculptural surface models (Alias) with your engineering team's CAD to create complex assemblies not possible with either tool alone.


Road bike experience from pro-level racing frames to fondo-friendly endurance rigs.  Experience with international teams on pioneering superbikes optimized with computational fluid dynamics, and experience with daily cruisers retailing for 90% less.  Mostly carbon but also steel, aluminum, magnesium (!) and Ti.


Have shaped hardtails, cross-country racers, all-mountain cruisers, enduro frames, downhill rigs, off-road singlespeeds, gravel bikes, and cyclocross frames.

Whether rigid, flexible by design, or fully suspended, the goal is to maximize structural integrity, optimize dynamic performance, and look great doing it.

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Experience with mid- and hub-drive systems from Bosch, Shimano, Fazua, Bafang, and Mahle/eBikeMotion.

Initially a skeptic, now a convert.  More bikes = fewer cars.  And just plain fun.

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TT / Triathlon

Personally a triathlete with experience designing both a non-UCI-legal integrated triathlon superbike with ergonomic features new to the industry and

a major brand UCI-legal time trial bike currently raced on the WorldTour with podium finishes at the Tour and several national championships.


Experience designing commuters, cruisers, and e-bikes.  Some for utility, for efficient commuting practicality.  Some for style...beach cruisers, retro designs...nostalgia for a simpler day.  All with the idea that a bicycle should combine thoughtful design with healthy dose of cool.

CAD surfacing

For those who already have a design, but need it executed in CAD - carbon sculpting in Alias is a skill developed over 20 years.

Automotive A-class surfacing.  Because no matter how good you are with Solidworks, it's not the appropriate tool for this:



Named on 20 patents and 10 international design awards including 4 Eurobike Gold Awards.  Podium finishes at the Tour de France,

World Enduro Series, and several national championships.  Niner Air 9 named one of the 25 most important bikes ever designed by MBA magazine.

Clients & Brands

Some of the 150+ brands for which millions of dollars of product has been personally designed in 25 years:



Underpromise.  Overdeliver.

Colorado based.  Occasional triathlete.  Extremely proud dad.

Passionate about creativity, personal integrity, and being easy to work with.  Request the same of my clients.

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Portfolio   |    Road + Gravel

Click any image for a larger view

Factor  |  Vis Vires
Factor  |  Vis Vires
Factor  |  Vis Vires
Niner MCR Sketch 2018
Road bike detail
Time trial bike concept
Time trial bike concept
Time trial bike concept
Raleigh  |  Pro-Conti Team Frame
TT aero bar design
Raleigh  |  Road frame design
Raleigh  |  RXC 'cross
TT concept
Raleigh  |  Pro-Conti Team Frame
Factor  |  Vis Vires 1st sketch
Factor  |  Vis Vires
Factor  |  Vis Vires
Raleigh  |  disc brake frame detail

Portfolio   |    MTB

Click any image for a larger view

Yeti  |  SB5    Velo Bike of the Year
Yeti  |  SB95
Niner  |  Air 9 Carbon
Niner  |  Air 9 Carbon RDO
eMTB  |  full-sus Bosch
eMTB  |  full-sus Bosch
Niner  |  Air 9 Carbon
Yeti  |  SB6
Yeti  |  SB4.5
Niner  |  Jet 9 Carbon RDO
Niner  |  Jet 9 Carbon RDO
Yeti  |  prototype
Downhill racing frame
Carbon  swingarm
Niner  |  Air 9 Carbon
Niner  |  Jet 9 Carbon RDO
Raleigh  |  Skarn
Niner  |  Jet 9 Carbon RDO
Niner  |  RIP 9 Carbon
Niner  |  RIP 9 Carbon
Niner  |  Jet 9 Carbon
Hardtail frame

Portfolio   |    Urban + Electric

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2020 LeMond Prolog
2020 LeMond Dutch
2020 LeMond Prolog
Urban Belt 1
Urban Belt 2
Arevo  |  Abu Dhabi Superbike
Arevo  |  Abu Dhabi Superbike
Columbia  |  retro cruiser
Arevo  |  eMoto
Arevo  |  eMoto
Arevo  |  eMoto
Wheels, Inc.  |   eScooter
Electra  |  Cruiser frame
Columbia  |  retro cruiser
Electra  |  cruiser
Electra  |  Indy + Vince
Raleigh  |  Citibike
Electra  |  cruiser
Raleigh  |  CitiBike commuter
Columbia  |  retro cruiser
Raleigh  |  CitiBike commuter
Electra  |  Straight 8

Portfolio   |    Cycling Related

Click any image for a larger view

Arevo  |  Wheels
FreeMotion  |  studio cycle
Cannondale  |  bottles + cages
Cycling trainer
Gravel bike saddle concept
Road bike saddle design
PowerTap hub.  Crank concept.
New Balance  |  sport sunglasses
Carbon wheelchair
CycleOps  |  Head unit concepts
LeMond Fitness
CycleOps  |  Indoor cycle
Cannondale | technical illustration
Cannondale  |  product animation