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How Frog bikes are quality tested

How Frog bikes are quality tested

A Frog bike isn't your typical children's bike! Not only are they specifically designed for kids based on scientific research, but we pride ourselves on the high-quality production of the entire bike that surpasses safety standards, from the wheels up to the handlebars. That’s why we think it is important to have our testing laboratory onsite in Wales, UK.

 

THE TESTING SUITE

In our manufacturing facility in Pontypool, Wales, Frog Bikes has built a state-of-the-art testing suite where an array of meticulous tests are carried out on our bikes to ensure the utmost safety! The testing facilities situated right on our premises, allow us to maintain our commitment to safety, have greater quality control, and expedite changes that may need to be made. We proudly boast a flawless track record - Frog bikes have never once failed a single safety test!


 

 

EXCEED SAFETY STANDARDS

Each Frog bike undergoes rigorous testing to adhere to a range of reputable standards, including:

  • BSI (British Standards Institute)
  • EN (European Norms)
  • ASTM (American Society for Testing and Materials), and
  • ISO (International Standards Body Organisation)

 

These tests are agreed upon by experts from the industry - think of them as a formula that describes the best way of doing something. Our comprehensive assessments encompass dimensional and functional checks, static loads, fatigue and impact testing that all ensure our bikes meet the minimum safety requirements and beyond, and also exhibit robustness, durability and long-lasting performance.


 

 

GOING THE EXTRA MILE

We always test above and beyond industry standards, and even conduct more robust testing protocols to ensure increased durability and safety of our bikes. This not only enhances the reliability of our bikes but also aids us in the research and development of new frames, forks and bicycle components. You’ll thank us for not compromising on quality and safety!


 

 

SUSTAINABLE GOALS

The testing also enables us to make improvements to the design of our bikes to reduce the materials required to make them, whilst still keeping the same quality and robustness. For example, we’ve introduced novel spoke patterns to reduce the amount of stainless steel in each wheel, as well as lighter bottom brackets, lighter cranks, and shorter seat tubes, reducing the steel and aluminium in each bike. This work will roll out through our range and help contribute to our Sustainable Development goals.


 

 

We take a look at what’s involved in the testing process at Frog Bikes…

 

 

Fatigue testing

A fatigue test involves repeatedly applying loads for up to 100,000 cycles to meet the minimum level of safety, and beyond; for our own improved quality and owners' peace of mind. By undertaking this rigorous process on the frame, fork, saddle, seat post, handlebars, pedals and cranks, we simulate not only their minimum lifespan but also their extended lifespan, to reveal their true potential.

 

The loads are measured using load cells and are accurately applied through pneumatic air cylinders. An electro-pneumatic control box manages the duration of each load, monitors repetitions achieved and will automatically cease operations when the target cycle count is reached. Our advanced testing system ensures safety is never compromised!

 

Here are the loads and cycles we fatigue test:

 

  • Frames: 
    • Horizontal Fatigue City and trekking +/- 450N (45Kg) for 100,000 cycles 
    • Horizontal Fatigue MTB + 1200N (120Kg) / - 600N (60Kg) for 100,000 cycles
    • Pedalling Fatigue City and trekking 1000N (100Kg) for 100,000 cycles 
    • Pedalling Fatigue MTB 1200N (120Kg) for 100,000 cycles 
    • Vertical Fatigue City and trekking 1000N (100Kg) for 100,000 cycles 
    • Vertical Fatigue MTB 1200N (120Kg) for 100,000 cycles

 

Frog's hybrid bikes exemplify outstanding durability, successfully enduring approximately 350,000 cycles of horizontal fatigue during testing. This remarkable achievement far surpasses the ISO 4210 standard's requirement of 100,000 cycles at the City and trekking level, demonstrating the superior quality and resilience of Frog's products.


 

 

Frog's balance bikes undergo rigorous testing too, which is not a requirement. This includes horizontal fatigue assessment. An exceptional example is the Tadpole + balance bike, which impressively surpassed even adult standards by reaching an astounding 1,000,000 cycles in testing!

 

  • Forks:
    • City and trekking +/-450N (45Kg) for 100,000 cycles
    • MTB +/- 650N (65Kg)  for 100,000 cycles
    • 1st pedal bikes +/-400N for 100,000 cycles
  • Handlebar and stem assemblies: 
    • City and trekking 200N (20Kg) out of phase for 100,000 cycles then 250N (25Kg) in phase for 100,000 cycles
    • MTB 270N (27Kg) out of phase for 100,000 cycles then 450N (45Kg) in phase for 100,000 cycles
  • Seatposts:
    • 1000N (100Kg) for 100,000 cycles
  • Saddles:
    • 1000N (100Kg) for 200,000 cycles
  • Pedals:
    • 80Kg city and trekking / 90Kg MTB for 100,000 revolutions for 100,000 revolutions

 

 


 

 

Impact testing

The purpose of impact testing is to simulate extreme events such as jumps and crashes by dropping weights onto components, or loading components with weights and dropping them through varying heights (depending on the application). This helps to ensure that our bikes are built to last and can endure the boundless adventures of children.

 

Here are the loads and cycles we impact test:

  • Frames: 
    • Loaded with up to 90Kg in weight and dropped through 200mm City and trekking / 300mm MTB
    • Loaded with 30Kg and dropped through 200mm for 1st pedal bikes
  • Forks: 
    • 22.5Kg dropped through 120mm 1st pedal bikes / 180mm City and trekking / 360mm MTB
  • Pedals: 
    • 15Kg dropped through 400mm


 

Static loads

 

Static loads are where we subject our safety critical components to high loads, seeking out for any signs of cracks, fractures, deflection, deformation or slippage beyond safe limits. This ensures that our bikes offer unyielding strength and durability.

 

Here are the loads and cycles we static load test:

  • Forks: 
    • Loaded with 1000N city and trekking / 1500N MTB with a deformation limit of 10mm
  • Handlebar and stem assembly: 
    • 600N (60Kg city and trekking / 1000N (100Kg) mtb for 1 minute
  • Handlebar stems: 
    • City and trekking 1600N (160Kg) for 1 minute looking for deformation max 10mm 
    • 2000N for 1 minute looking for fractured and cracking / MTB 1600N (160Kg) for 1 minute looking for deformation max 10mm 
    • 2600N for 1 minute looking for fractures and cracking
  • Saddles: 
    • 650N vertically / 250N horizontally with no movement allowed
    • 1200N vertically checking for breaks
  • Seat posts: 
    • 2000N (200Kg) for 1 minute
  • Pedals: 
    • 1500N for 5 minutes 
       

 

Dimensional checks

Dimension checks are made to every major component and the entire bike to ensure that components interact as they should. We meticulously evaluate safety clearances such as the precise reach distances in brake levers, finger traps, toe clearance, pedal ground clearance, angles of tilt, gaps between tyres and the frame and insertion depths. These minute details are crucial for both safety and performance.

 

Functional and performance checks

With unwavering attention, we make a multitude of functional checks such as tightening torques, measuring the force to remove hand grips in differing environmental conditions from cold and wet to hot, measuring the force required to pull the brake levers and operate quick release mechanisms, ensuring seamless operation when it matters most. We detect any stiff spots and slackness in bearings and assemblies, sharp edges and dangerous protrusions.

 

We also examine the distribution of a rider’s weight through the bicycle, ensuring optimal balance and performance. To truly push the limits we put our bikes through braking performance tests, physically riding them in both wet and dry conditions. With precision and accuracy, we measure braking distances at varying speeds and rider weights, guaranteeing excellent braking performance.

 

THE STANDARDS FROG BIKES MEET 
 

Bike Range Bike Model Standards met
Balance Bike Tadpole Mini  EN71 (Toys) and ASTM F963-19 (Toys)
Balance Bike Tadpole EN71 (Toys) and ASTM F963-19 (Toys)
Balance Bike Tadpole Plus EN71 (Toys) and ASTM F963-19 (Toys)
First Pedal Frog 40 ISO 8098 and CPSC 1512 (CFR 1512)
First Pedal Frog 44 ISO 8098 and CPSC 1512 (CFR 1512)
First Pedal Frog 47 ISO 4210 and CPSC 1512 (CFR 1512)
Hybrid Bike Frog 53 ISO 4210 and CPSC 1512 (CFR 1512)
Hybrid Bike Frog 61 ISO 4210 and CPSC 1512 (CFR 1512)
Hybrid Bike Frog 67 ISO 4210 and CPSC 1512 (CFR 1512)
Hybrid Bike Frog 73 ISO 4210 and CPSC 1512 (CFR 1512)
Hybrid Bike Frog 78 ISO 4210 and CPSC 1512 (CFR 1512)
Road Bike Frog Road 58 ISO 4210 and CPSC 1512 (CFR 1512)
Road Bike Frog Road 67 ISO 4210 and CPSC 1512 (CFR 1512)
Road Bike Frog Road 70 ISO 4210 and CPSC 1512 (CFR 1512)
Track Bike Frog Track 58 ISO 4210 Frame and fork only
Track Bike Frog Track 67 ISO 4210 Frame and fork only
Track Bike Frog Track 70 ISO 4210 Frame and fork only
Mountain Bike Frog MTB 62 ISO 4210 and CPSC 1512 (CFR 1512)
Mountain Bike Frog MTB 69 ISO 4210 and CPSC 1512 (CFR 1512)
Mountain Bike Frog MTB 72 ISO 4210 and CPSC 1512 (CFR 1512)
City Bike Frog City 53 ISO 4210 and CPSC 1512 (CFR 1512)
City Bike Frog City 61 ISO 4210 and CPSC 1512 (CFR 1512)
City Bike Frog City 67 ISO 4210 and CPSC 1512 (CFR 1512)

 

Our commitment to excellence is reflected in every meticulous test conducted in our state-of-the-art facility in Wales, UK. With a flawless track record and a steadfast commitment to safety and reliability, Frog Bikes remains your trusted partner in providing premium quality for young riders.  
 

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