Project 1 — Design and structural validation for urban competition
A local manufacturer needed an ultralight road bicycle frame capable of withstanding dynamic loads without plastic deformation, while maintaining a weight under 1.2 kg. Existing designs failed fatigue tests after 10,000 cycles.
Parametric modeling in SolidWorks with finite element analysis (FEA) to optimize tube geometry and welded joints. 4130 steel and 6061-T6 alloys were evaluated, prioritizing the strength-to-weight ratio.
12 design iterations were generated with variations in thicknesses and curvature radii. Each iteration was simulated under static and cyclic loads (ISO 4210 standard). The final version incorporated an internal reinforcement in the seat tube.
Final frame weighing 1.15 kg, with a tensile strength of 780 MPa and a service life exceeding 50,000 cycles without failure. Manufacturing cost was reduced by 18% through material optimization.
Client: UrbanCycle Components
Duration: 14 weeks (modeling + testing)
From technical concept to patent, each stage follows a flow of mechanical modeling and structural validation.
Analysis of loads, materials, and mechanical frame geometry.
Parametric design of bearings and structural joints in CAD.
Stress and fatigue analysis in high-grade steel.
Manufacturing quote with precision tolerances.
Physical validation of the frame and bearings on a test bench.
Technical documentation and registration of precision components.