Road Bicycle Bracket Development
This project involved working closely with a client to design and manufacture two custom mounting brackets for a road bike. The goal was to translate physical requirements and hand drawn templates into functional, production ready parts that could withstand the constant vibrations and loads of road use.
Front Bracket
Working from card templates and photographs provided by the client, the initial geometry was traced and scaled into a parametric CAD model. This phase was focused on establishing a baseline fitment before moving into structural refinements. The front bracket consisted of two parts, a mounting plate and the central block.
Several iterations were produced in PETG to test the real world fit against the bike frame. This stage was crucial for identifying early surface finish issues and mounting hardware. Through a consistent feedback loop, I adjusted the design to accommodate client requests for better clearance and a more streamlined profile.
Once the design was finalised through physical testing, it was produced in ASA for long term UV resistance. To simplify the assembly, M5 heat set inserts were integrated, allowing for a secure mount without the need for secondary nuts.
Rear Bracket
Building on the success of the first part, I took direct measurements from the bike to ensure precision for the second, more complex bracket. Allowing for tighter tolerances and a more integrated look on the frame.
To optimize the bracket for weight and strength, I utilized generative design as a reference. By inputting the mounting points and expected loads, such as fluids and road impact, the software suggested an optimal design. I then used these results as inspiration for a manual CAD rebuild. This was verified through FEA (Finite Element Analysis) to guarantee the part would remain rigid and reliable even when subjected to the constant vibrations of rough road surfaces.
Throughout the process, client feedback was involved to ensure the outcome met expectations. This iterative design process ensured the geometry was optimised for fitment and aesthetics in line with customer expectations.
The final version was produced in ASA, utilizing heat set inserts to maintain a professional, low profile finish. Splitting the bracket into a two part assembly allowed for easier installation and minimized material waste during the printing process.
The final components provided a perfect fit that met both the structural requirements for road racing and the aesthetic standards of the client. By combining traditional metrology with modern algorithmic tools and constant stakeholder feedback, the project successfully transitioned from a card template to a high performance engineering solution.