FOX engaged FORM3, to collaborate closely with their Mechatronics and Component engineering teams. Together, they developed the next-generation wireless Live Valve suspension system, a new wireless dropper post, and wireless handlebar controls for high performance riders. All components were designed with a focus on enhancing rider experience and performance. The incredibly fast electronics are supported by ergonomics, haptics, and mechanisms that are tight and fast so that the entire system-feel is next level.
Desktop Section
NEO
FOX
Overview
CLIENT
FOX
ROLE
Design Research
Concept Exploration
Ergonomic Testing and Iteration
Internal Component Configuration
Prototyping and Testing
Industrial Design
CAD development
Concept Exploration
Ergonomic Testing and Iteration
Internal Component Configuration
Prototyping and Testing
Industrial Design
CAD development
Redefining Rider Control
Key Challenges
In the evolution of mountain biking, riders have continually faced challenges with traditional cable-actuated control systems. These mechanical linkages, responsible for managing suspension adjustments and seat post positioning, often introduced complexities such as increased weight, potential for cable stretch or breakage, and susceptibility to environmental factors like mud and water. Such issues could degrade performance, necessitate frequent maintenance, and detract from the overall riding experience.
Recognizing these limitations, FOX sought to revolutionize rider control by eliminating the mechanical constraints inherent in traditional systems. Their goal was to develop wireless solutions that would offer riders more intuitive, reliable, and efficient control over their bike's critical functions. This vision led to the creation of advanced technologies like the Live Valve suspension system and the Transfer Neo wireless dropper post. These innovations aimed to enhance the riding experience by providing seamless, responsive adjustments without the drawbacks of cables and manual interventions.
Recognizing these limitations, FOX sought to revolutionize rider control by eliminating the mechanical constraints inherent in traditional systems. Their goal was to develop wireless solutions that would offer riders more intuitive, reliable, and efficient control over their bike's critical functions. This vision led to the creation of advanced technologies like the Live Valve suspension system and the Transfer Neo wireless dropper post. These innovations aimed to enhance the riding experience by providing seamless, responsive adjustments without the drawbacks of cables and manual interventions.
FORM3 was tasked with shaping a product system around a shared battery format and established constraints for the shock and dropper post controller. User interaction was of great importance. We needed to designing ergonomic, intuitive controls, and components that maintained premium aesthetics, reliability, and seamless integration.Form3 faced several key challenges in this project:
• Ensuring intuitive ergonomics, accessible button placement, and secure mounting during intense riding.
• Creating a unified design language across multiple bike components.
• Providing tactile feedback without visual confirmation.
• Achieving robust waterproofing and dust resistance (IP67/IPX9K).
• Engineering compact internal layouts with integrated battery functionality.
• Optimizing component attachment for rapid setup and compatibility with brake and frame models, and cockpit mounting standards.
• Synthesized feedback and direction from Fox engineering and marketing teams across North America
• Creating a unified design language across multiple bike components.
• Providing tactile feedback without visual confirmation.
• Achieving robust waterproofing and dust resistance (IP67/IPX9K).
• Engineering compact internal layouts with integrated battery functionality.
• Optimizing component attachment for rapid setup and compatibility with brake and frame models, and cockpit mounting standards.
• Synthesized feedback and direction from Fox engineering and marketing teams across North America
With FOX NEO, we weren’t just designing individual components—we were building a unified rider experience. Every interaction, from the tactile feel of a button to the secure integration of the battery, was obsessively refined to deliver performance that disappears into the ride.
Robbie Roberts - Principle at Form3
Powered by Neo —
the fastest wireless protocol in cycling
Designed for Intuitive Performance
Traditional wired and cable actuated systems are slow and complext to maintain and setup. Electronic integration has the promise of eliminating that noise. The NEO electronic system simply works to remove all of the fuss. If optimizes every moment of your ride without thinking, The user trade-off is the need to manage a battery. FORM3 designed a custom battery enclosure and charger that streamlined that experience with easy and secure mounting that allows fast swap-out. A 4 segment custom RGD LED array and light guide around the power button provide clear updates to the user on battery level and also supports setup.
Wireless Live Valve Suspension System
• Conducted extensive testing to optimize ergonomics, including button shape, force, and position, ensuring intuitive access while riding.
• Developed robust bump sensor mounts utilizing universal brake mounts, optimized to fit all known brake standards through co-molding techniques.
• Engineered to IP67/IPX9K standards for robust environmental protection, safeguarding internal electronics.
• Developed robust bump sensor mounts utilizing universal brake mounts, optimized to fit all known brake standards through co-molding techniques.
• Engineered to IP67/IPX9K standards for robust environmental protection, safeguarding internal electronics.
Dropper Post
• Optimized internal layouts to integrate a custom unified battery platform and maintain tire clearance goals while emphasizing ease of attachment, detachment, and sealing.
• Ensured cohesive aesthetics across components, selecting materials and finishes that enhance durability and visual appeal.
• Developed and assembly configuration for electronic housings to dovetail with mechanical constraints.
• Ensured cohesive aesthetics across components, selecting materials and finishes that enhance durability and visual appeal.
• Developed and assembly configuration for electronic housings to dovetail with mechanical constraints.
Wireless Handlebar Controls
• Designed a mechatronic solution with quick action that provides clear tactile feedback with a very fast response time to unlock performance un-attainable with a cable system.
• Created a modular mounting system compatible with major brake lever standards (SRAM Match Maker, Shimano I-spec EVO).
• Iterated through a range of ergonomic approaches and validated directions early in the process with controlled user groups to ensure alignment with end users and the best user experience amongst competitors.
• Defined mechanisms and identified manufacturing methodologies for key components.
• Created a modular mounting system compatible with major brake lever standards (SRAM Match Maker, Shimano I-spec EVO).
• Iterated through a range of ergonomic approaches and validated directions early in the process with controlled user groups to ensure alignment with end users and the best user experience amongst competitors.
• Defined mechanisms and identified manufacturing methodologies for key components.
Battery
• Custom-designed, shared battery platform used across both the wireless dropper post and Live Valve suspension. Developed to streamline the FOX NEO system with a unified power solution.
• FORM3 optimized product shapes and internal configurations to seamlessly integrate the battery into both components.
• Worked through key mechanical and manufacturing challenges inherence in a custom battery enclosure to be used in a rigourous environment
• Designed for intuitive attachment and detachment, simplifying user interaction and maintenance.
• Battery design ensures a secure, environmentally sealed fit, maintaining durability and waterproofing across all use cases.
• Visually harmonized to feel native to each product, reinforcing the cohesive aesthetic of the NEO system.
• FORM3 optimized product shapes and internal configurations to seamlessly integrate the battery into both components.
• Worked through key mechanical and manufacturing challenges inherence in a custom battery enclosure to be used in a rigourous environment
• Designed for intuitive attachment and detachment, simplifying user interaction and maintenance.
• Battery design ensures a secure, environmentally sealed fit, maintaining durability and waterproofing across all use cases.
• Visually harmonized to feel native to each product, reinforcing the cohesive aesthetic of the NEO system.
Bump Sensors
• Explored a range of mounting approaches settling on the brake calliper mounts for ease of setup across a range of bike frames.
• Optimized the mounting mechanism and housing shape for compatibility with nearly all brake models.
• Developed a mechanical assembly the solves easy of battery access and a simple sealing methodology.
• Optimized the mounting mechanism and housing shape for compatibility with nearly all brake models.
• Developed a mechanical assembly the solves easy of battery access and a simple sealing methodology.
This project was defined by deep collaboration with Fox’s talented engineering team. We coordinated inputs and testing from diverse teams across North America—navigating a mix of established and undefined elements to bring everything to market together.
Robbie Roberts - Principle at Form3
Manufacturing and Integration
Bringing the FOX NEO system to life required more than great design—it demanded seamless coordination with FOX’s engineering and manufacturing teams. FORM3 ensured every detail was production-ready, from CAD handoff to real-world assembly.
• Integrated closely with the FOX engineering team to effectively address project challenges.
• Delivered fully detailed CAD files, ensuring smooth transition into manufacturing.
• Simplified installation and maintenance through modular attachments and tool-less battery access.
• Delivered fully detailed CAD files, ensuring smooth transition into manufacturing.
• Simplified installation and maintenance through modular attachments and tool-less battery access.
Validation and Performance
Design is only as good as it performs on the trail. FORM3’s solutions were rigorously tested through competitive racing and field validation to prove their durability, precision, and rider-focused design.
• Conducted extensive validation through low-volume prototype production and real-world race testing, achieving multiple World Cup podiums.
• Created highly optimized internal layouts balancing performance, size, and weight.
• Solved complex ergonomic challenges through iterative testing with controlled user groups, providing intuitive control and clear tactile feedback even in challenging riding conditions.
• Achieved seamless integration of dropper post and suspension functions into a compact, premium-feeling unit.
• Created highly optimized internal layouts balancing performance, size, and weight.
• Solved complex ergonomic challenges through iterative testing with controlled user groups, providing intuitive control and clear tactile feedback even in challenging riding conditions.
• Achieved seamless integration of dropper post and suspension functions into a compact, premium-feeling unit.
All Winner 2025 Components (Offroad)
FOX Factory | Live Valve Neo
All Winner 2025 Components (Offroad)
Fox Factory | Neo Wireless Protocol
Mobile Section
NEO
FOX
Overview
FOX engaged FORM3, to collaborate closely with their Mechatronics and Component engineering teams. Together, they developed the next-generation wireless Live Valve suspension system, a new wireless dropper post, and wireless handlebar controls for high performance riders. All components were designed with a focus on enhancing rider experience and performance. The incredibly fast electronics are supported by ergonomics, haptics, and mechanisms that are tight and fast so that the entire system-feel is next level.
CLIENT
FOX
ROLE
Design Research
Concept Exploration
Ergonomic Testing and Iteration
Internal Component Configuration
Prototyping and Testing
Industrial Design
CAD development
Concept Exploration
Ergonomic Testing and Iteration
Internal Component Configuration
Prototyping and Testing
Industrial Design
CAD development
Redefining Rider Control
A Revolution in Mountain Biking
In the evolution of mountain biking, riders have continually faced challenges with traditional cable-actuated control systems. These mechanical linkages, responsible for managing suspension adjustments and seat post positioning, often introduced complexities such as increased weight, potential for cable stretch or breakage, and susceptibility to environmental factors like mud and water. Such issues could degrade performance, necessitate frequent maintenance, and detract from the overall riding experience.
Recognizing these limitations, FOX sought to revolutionize rider control by eliminating the mechanical constraints inherent in traditional systems. Their goal was to develop wireless solutions that would offer riders more intuitive, reliable, and efficient control over their bike's critical functions. This vision led to the creation of advanced technologies like the Live Valve suspension system and the Transfer Neo wireless dropper post. These innovations aimed to enhance the riding experience by providing seamless, responsive adjustments without the drawbacks of cables and manual interventions.
Recognizing these limitations, FOX sought to revolutionize rider control by eliminating the mechanical constraints inherent in traditional systems. Their goal was to develop wireless solutions that would offer riders more intuitive, reliable, and efficient control over their bike's critical functions. This vision led to the creation of advanced technologies like the Live Valve suspension system and the Transfer Neo wireless dropper post. These innovations aimed to enhance the riding experience by providing seamless, responsive adjustments without the drawbacks of cables and manual interventions.
FOX partners with Form3
FORM3 was tasked with shaping a product system around a shared battery format and established constraints for the shock and dropper post controller. User interaction was of great importance. We needed to designing ergonomic, intuitive controls, and components that maintained premium aesthetics, reliability, and seamless integration.
Key Challenges
Form3 faced several key challenges in this project:
• Ensuring intuitive ergonomics, accessible button placement, and secure mounting during intense riding.
• Creating a unified design language across multiple bike components.
• Providing tactile feedback without visual confirmation.
• Achieving robust waterproofing and dust resistance (IP67/IPX9K).
• Engineering compact internal layouts with integrated battery functionality.
• Optimizing component attachment for rapid setup and compatibility with brake and frame models, and cockpit mounting standards.
• Synthesized feedback and direction from Fox engineering and marketing teams across North America
• Ensuring intuitive ergonomics, accessible button placement, and secure mounting during intense riding.
• Creating a unified design language across multiple bike components.
• Providing tactile feedback without visual confirmation.
• Achieving robust waterproofing and dust resistance (IP67/IPX9K).
• Engineering compact internal layouts with integrated battery functionality.
• Optimizing component attachment for rapid setup and compatibility with brake and frame models, and cockpit mounting standards.
• Synthesized feedback and direction from Fox engineering and marketing teams across North America
With FOX NEO, we weren’t just designing individual components—we were building a unified rider experience. Every interaction, from the tactile feel of a button to the secure integration of the battery, was obsessively refined to deliver performance that disappears into the ride.
Robbie Roberts -
Principle at Form3
Powered by Neo —
the fastest wireless protocol in cycling
Designed for Intuitive Performance
Traditional wired and cable actuated systems are slow and complext to maintain and setup. Electronic integration has the promise of eliminating that noise. The NEO electronic system simply works to remove all of the fuss. If optimizes every moment of your ride without thinking, The user trade-off is the need to manage a battery. FORM3 designed a custom battery enclosure and charger that streamlined that experience with easy and secure mounting that allows fast swap-out. A 4 segment custom RGD LED array and light guide around the power button provide clear updates to the user on battery level and also supports setup.
Wireless Live Valve Suspension System
Learn More
• Conducted extensive testing to optimize ergonomics, including button shape, force, and position, ensuring intuitive access while riding.
• Developed robust bump sensor mounts utilizing universal brake mounts, optimized to fit all known brake standards through co-molding techniques.
• Engineered to IP67/IPX9K standards for robust environmental protection, safeguarding internal electronics.
• Developed robust bump sensor mounts utilizing universal brake mounts, optimized to fit all known brake standards through co-molding techniques.
• Engineered to IP67/IPX9K standards for robust environmental protection, safeguarding internal electronics.
Dropper Post
Learn More
• Optimized internal layouts to integrate a custom unified battery platform and maintain tire clearance goals while emphasizing ease of attachment, detachment, and sealing.
• Ensured cohesive aesthetics across components, selecting materials and finishes that enhance durability and visual appeal.
• Developed and assembly configuration for electronic housings to dovetail with mechanical constraints.
• Ensured cohesive aesthetics across components, selecting materials and finishes that enhance durability and visual appeal.
• Developed and assembly configuration for electronic housings to dovetail with mechanical constraints.
Wireless Handlebar Controls
Learn More
• Designed a mechatronic solution with quick action that provides clear tactile feedback with a very fast response time to unlock performance un-attainable with a cable system.
• Created a modular mounting system compatible with major brake lever standards (SRAM Match Maker, Shimano I-spec EVO).
• Iterated through a range of ergonomic approaches and validated directions early in the process with controlled user groups to ensure alignment with end users and the best user experience amongst competitors.
• Defined mechanisms and identified manufacturing methodologies for key components.
• Created a modular mounting system compatible with major brake lever standards (SRAM Match Maker, Shimano I-spec EVO).
• Iterated through a range of ergonomic approaches and validated directions early in the process with controlled user groups to ensure alignment with end users and the best user experience amongst competitors.
• Defined mechanisms and identified manufacturing methodologies for key components.
Battery
Learn More
• Custom-designed, shared battery platform used across both the wireless dropper post and Live Valve suspension. Developed to streamline the FOX NEO system with a unified power solution.
• FORM3 optimized product shapes and internal configurations to seamlessly integrate the battery into both components.
• Worked through key mechanical and manufacturing challenges inherence in a custom battery enclosure to be used in a rigourous environment
• Designed for intuitive attachment and detachment, simplifying user interaction and maintenance.
• Battery design ensures a secure, environmentally sealed fit, maintaining durability and waterproofing across all use cases.
• Visually harmonized to feel native to each product, reinforcing the cohesive aesthetic of the NEO system.
• FORM3 optimized product shapes and internal configurations to seamlessly integrate the battery into both components.
• Worked through key mechanical and manufacturing challenges inherence in a custom battery enclosure to be used in a rigourous environment
• Designed for intuitive attachment and detachment, simplifying user interaction and maintenance.
• Battery design ensures a secure, environmentally sealed fit, maintaining durability and waterproofing across all use cases.
• Visually harmonized to feel native to each product, reinforcing the cohesive aesthetic of the NEO system.
Bump Sensors
Learn More
• Explored a range of mounting approaches settling on the brake calliper mounts for ease of setup across a range of bike frames.
• Optimized the mounting mechanism and housing shape for compatibility with nearly all brake models.
• Developed a mechanical assembly the solves easy of battery access and a simple sealing methodology.
• Optimized the mounting mechanism and housing shape for compatibility with nearly all brake models.
• Developed a mechanical assembly the solves easy of battery access and a simple sealing methodology.
Manufacturing and Integration
Learn More
Bringing the FOX NEO system to life required more than great design—it demanded seamless coordination with FOX’s engineering and manufacturing teams. FORM3 ensured every detail was production-ready, from CAD handoff to real-world assembly.
• Integrated closely with the FOX engineering team to effectively address project challenges.
• Delivered fully detailed CAD files, ensuring smooth transition into manufacturing.
• Simplified installation and maintenance through modular attachments and tool-less battery access.
• Delivered fully detailed CAD files, ensuring smooth transition into manufacturing.
• Simplified installation and maintenance through modular attachments and tool-less battery access.
Validation and Performance
Learn More
Design is only as good as it performs on the trail. FORM3’s solutions were rigorously tested through competitive racing and field validation to prove their durability, precision, and rider-focused design.
• Conducted extensive validation through low-volume prototype production and real-world race testing, achieving multiple World Cup podiums.
• Created highly optimized internal layouts balancing performance, size, and weight.
• Solved complex ergonomic challenges through iterative testing with controlled user groups, providing intuitive control and clear tactile feedback even in challenging riding conditions.
• Achieved seamless integration of dropper post and suspension functions into a compact, premium-feeling unit.
• Created highly optimized internal layouts balancing performance, size, and weight.
• Solved complex ergonomic challenges through iterative testing with controlled user groups, providing intuitive control and clear tactile feedback even in challenging riding conditions.
• Achieved seamless integration of dropper post and suspension functions into a compact, premium-feeling unit.
This project was defined by deep collaboration with Fox’s talented engineering team. We coordinated inputs and testing from diverse teams across North America—navigating a mix of established and undefined elements to bring everything to market together.
Robbie Roberts - Principle at Form3