How We Designed the Award-Winning Ari Shafer Gravel Bike

Take an inside look at how the Ari Shafer gravel bike was designed — straight from the desk of Ari Bikes’ industrial designer, Spencer and the team.

Checkout our bikes here: https://bit.ly/49RdM0O

In this video, we break down the complete gravel bike design process, from early concept sketches and hand drawings to CAD development, 3D-printed prototypes, carbon frame samples, real-world test riding, and final production details. The Ari Shafer has quickly become an award-winning gravel bike, and this behind-the-scenes look shows the design thinking, iteration, and testing that shaped the final bike.

You’ll see how rough sketches evolve into digital 3D files, why size-specific geometry and chainstay lengths matter, and how tire clearance, compliance, and comfort were built directly into the frame design. The video also covers component testing, gearing decisions, and how real riding — from daily commuting to bikepacking trips — influenced the final setup.

Spencer also shares a lesser-known design detail that most riders never notice, including the story behind the Shafer’s integrated storage system and the many iterations it took to get it right.

If you’ve ever wondered how a high-end gravel bike is designed, or what separates an award-winning gravel bike from the rest, this is the process most people never get to see.

00:00 – Intro
00:20 – Starting with Concept Sketches
02:35 – CAD Development
04:24 – 3D Printing Benefits
06:03 – Testing & Building Frame Samples
09:06 – Hidden Frame Feature
10:11 – Colors & Graphics
16:35 – Final Thoughts