Shredmate connected MTB sensor — full hardware, firmware, Bluetooth and app development. Product design case study by Fettle, Bristol

Case Study: Shredmate

A connected mountain bike sensor — founded by Fettle co-founder Chris Irlam.

Shredmate is a Bluetooth-connected sensor system for mountain biking, measuring jump air time, G-force, speed, and trail data in real time.

Chris delivered the entire product: hardware design, embedded firmware on an nRF52 BLE microcontroller, Android and iOS applications, production test rigs, and manufacturing.

Why it matters

Chris has done exactly what many of our start-up clients are trying to do — take a hardware product from an idea to a funded, manufactured, shipped reality.

The Challenge

Traditional bike computers are designed for the road.

ShredMate needed to be designed for the chaos of mountain biking: harsh terrain, suspension chatter, mud and unpredictable rider input.

Key requirements for ShredMate included:

  • Detecting the MTB events riders actually cared about.

  • Work reliably in mud, spray, vibration and impacts.

  • Stay compact, low-power and robust.

  • Show results clearly: where, what, and how it compare.

Shredmate durability and performance testing — ruggedised connected sports device engineered by Fettle Product Design, Bristol

The Approach

After defining the product brief, we explored concepts ranging from a standalone bike computer with an integrated display to a compact sensor paired with a mobile app.

We rapidly prototyped and tested with users. Feedback showed an on-bike screen added little value for mountain bikers: review happens after the ride as rough terrain makes a display hard to check. The screen also added cost and complexity due to high-spec electronics and a rechargeable battery.

We therefore pivoted to a compact, fork-mounted device with a mobile app. This reduced complexity and cost by using a low-power Bluetooth microcontroller and accelerometer, enabling up to a year of operation on a button-cell battery. Removing on-device buttons also avoided mechanical complexity and the challenge of preventing water ingress.

For durability, the enclosure was ultrasonically welded for a robust seal, while the battery stayed user-replaceable via a quarter-turn hatch.

To validate real-world performance, we captured hundreds of rides of accelerometer data with a custom logger across a wide range of riders and styles. We iteratively developed the jump detection algorithm offline in MATLAB, then translated the final model into embedded firmware for the device.

Shredmate PCB, enclosure and electronic module — electro-mechanical product design and engineering by Fettle, Bristol UK
Shredmate mechanical design for manufacture — enclosure, housing and component engineering by Fettle Product Design, Bristol

The Outcome

Following a successful Kickstarter campaign, ShredMate progressed from prototype to production and was delivered on time, on budget and to specification. The companion apps maintain ratings above 4.2★, reflecting a strong and reliable day-to-day user experience.

Shredmate connected mountain bike sensor — consumer hardware product designed and engineered by Fettle, Bristol UK
Shredmate mobile app interface — Bluetooth connected product hardware-software integration by Fettle Product Design, Bristol

What we did

  • Industrial design

  • Mechanical design

  • UX design

  • Test rigs

  • Iterative prototype and test builds

  • Prototype & production electronics

  • Sensor algorithm

  • Embedded firmware

  • Mobile app development.

  • Contract manufacturer management

  • Production support