Design and Geometrical Optimization of a New Mountain Bike Frame

The mountain bike industry has made impressive progress in serial production since the early 1980s. Initially lacking suspension mechanisms and constructed with heavy materials, manufacturers gradually integrated lightweight materials like aluminum and carbon fiber, which are now widely used. This progress extended to associated systems such as dampers to improve customer comfort and performance, the bicycle industry focused on developing lighter components and reducing overall weight. Additive manufacturing played a crucial role, enabling flexible fabrication and reverse engineering, allowing the creation of unique components based on topologically optimized geometries. This approach facilitated automated production of personalized bike devices tailored to individual preferences. Topological optimization, a technique in structural analysis, emerged as a means to reduce weight while maintaining mechanical functionality, particularly in weight-critical applications. It found a successful application in additive manufacturing technologies like selective laser sintering, enabling the production of complex geometries. Customizing bike components based on customer desires reduced material usage and overall weight, leading to improved performance and comfort. The manuscript discusses the development of a geometrically optimized mountain bike frame using topological optimization algorithms. The focus is on reducing frame weight through additive manufacturing, with a dimensioning study analyzing loads and adhering to safety standards. Carbon fiber 800H, known as Torayca T800H, was chosen as the material for optimization and simulations. This study represents a significant advancement in reducing weight and customizing mountain bikes through additive manufacturing. The application of topological optimization and advanced materials contributes to enhanced performance, comfort, and rider satisfaction.