The development and prototyping of a new product is a very exciting time in the life of our little brand. So, for once, we’re taking a little time to look behind the scenes of La Bananadry, which will be released tomorrow. No fewer than 6 complete prototypes were required to finalize the design of this new benchmark. Between each stage, there were tests, changes of solution and new materials. Let’s briefly retrace the path from the first drawing to the product now available 🙂
Starting point :
For almost 4 years now, we’ve been offering the Musette, a handlebar bag that converts into a hip bag. We and you still like it as much as ever, but it’s a bag that we’ve always defined for daily cycling use. Although many of you have used it on your travels, it wasn’t originally intended for that purpose, and we’d long wanted to make a version completely adapted for bikepacking. As always, the idea began to take shape in the corners of our notebooks. Before continuing to think, we had to establish the basic characteristics we wanted the project to have.
Here are a few specifications we drew up ourselves at the start of the project:
- Waterproof loading
- Stable attachment to handlebar
- Adjustable volume
- Convertible in hip bag
- Multiple access
- Waterproof front pocket
- Attractive design for everyday use
- Long durability (abrasion resistance)
On prototype?
Starting to prototype is not an easy step for us. First, we have to be convinced that the idea is good, and that after a certain amount of work, we’ll be excited to present it under the brand. Secondly, we have to make time for ourselves, and manage to put the rest of our other missions, like framebuilding, communication, shop management etc etc, on hold.
At the beginning of 2024, we were lucky to welcome Isaure, a 4th year textile design student at HEAR, for an internship. We worked together, and Isaure spent many long hours at the machine sewing our ideas. Here are 5 prototypes we went through. Between each complete prototype, we also isolated certain parts to test sewing details. Here’s a quick summary of the iterations.
Prototype N°1: This prototype enabled us to validate the general concept of the Bananadry, this drybag hipbag hybrid. It works well on the handlebar, access from both sides is pleasant, but we thought that a little memo system to remember which side the cookie was stored on would be a plus. In particular, we wondered whether the double rolltop drybag was appropriate to use when the bag is in fanny pack mode, and after testing, we’re pretty convinced. We then decided to go for a smaller volume and a different volume adjustment system. The system for attaching it to the handlebars is still rather basic at this point.
Prototype N°2: This second prototype features a central volume made from several pieces of tarpaulin, with the idea of reducing size of patterns to be able to work with small leftovers. We also wanted to test the effect of a two-tone front. This solution facilitates the manufacture of the watertight closure, but the seams between the yokes stiffen the central cylinder and makes it hard to fold. We modified the adjustment system with the addition of two clips, and worked more precisely on the handlebar interface. Time to go for a ride and test it on the bike 🙂
Prototype N°3: The previous prototype was very conclusive on several points of our brief, and we could already validate a few design choices at this stage. Prototype N°3 allows us to go more into the details: we refine the dimensions of the patterns, add attachment points all over the bag, perfect the positioning of the seams to improve waterproofing, and push the details further to arrive at a marketable product.
Prototype N°4: In all our prototyping work, there’s a key moment: the first prototype made by Libre Objet, the social workshop who takes in charge the production of all our bags. We are now entering the formalization phase, i.e. making the product ready for “mass” production (30 pieces for this first batch). Porchia, Libre Objet’s workshop manager, creates this prototype, and at each stage we check whether our choices are ok with their habits and production line. At the end of this prototype, we have to be able to move on to editing the plans for all the patterns, and designing the marking and cutting templates.
Prototype N°5: We’ve just got our hands on some new textiles that are just in time: super-waterproof, super-light fabrics. We’re able to push the quality of this bag even further, replacing the Cordura inserts with membrane textiles and nylon ripstop. A final prototype is needed to test the durability of the materials under intensive use. After our battery of tests with the previous prototype, we also decided to incorporate a rigid structure into the handlebar bag mode, using a stainless steel tube. Prototype n°5 will be tested and approved on an intense 4-day gravel trip in the Morvan, and on the Vosges Express event. We’re all set!
Release
The Bananadry is ready. We’ve finalized the design, chosen the materials and colors, and finished making the first series. What remains to be done is to fine-tune the product price in relation to the timed production on this first batch, photograph all the references, edit the product page, write the article you’re reading right now, and prepare a post to announce the release. As we finish these lines, we’ve just returned from the Bespoked show in Dresden, where we showed this new bag to the public for the first time, and the feedback has been super enthusiastic.
See you tomorrow to find La Bananadry in our store 🙂
