Setback (March – April 2025)

The road to series production is never a straight line.

After several intensive months of redevelopment, it became clear at the beginning of 2025: the TOURELLY cleat was too complex. Too many parts, too complicated to assemble, too difficult to manufacture. So we decided to simplify it step by step – without losing functionality.

From March 2025 onward, we started a series of tests, compression trials and material analyses to make the cleat slimmer, more robust and lighter.

In parallel, we were already preparing for the next Eurobike 2025 – and faced some important questions: Which version do we show? Which cleat and pedal setup represents TOURELLY best?

This phase was defined by continuous improvements – not in big leaps, but in many small details that, together, make the difference.

We simplified the entire system design:

• The cleat became more functional, lighter and more material-efficient.
• The pedal received an optimized shape, becoming visually cleaner and technically more coherent.
• The Q-factor adjustment was redesigned – simpler, more intuitive and more reliable.
• The bearing arrangement was reworked to make assembly, servicing and replacement significantly easier.

In parallel, we conducted material tests, weight measurements and initial simulations. We wanted to understand every gram.

But then came the setback: during an impact test, the axle failed. An unexpected moment that reminded us that progress also means finding weaknesses.

Instead of frustration, it triggered the next step: a complete redesign of the axle. We analysed the fracture, examined stress patterns and adjusted geometry and material selection.

This process took time – but it brought us closer to series readiness than any flawless test could have.