The primary objective of this project was to develop a lightweight yet durable bicycle frame suitable for everyday urban use. The frame was modelled in SolidWorks and structurally assessed using FEA simulations to validate its performance under realistic loading conditions. Emphasis was placed on ergonomics, strength-to-weight ratio, and manufacturability.

This project focuses on the development and structural evaluation of a bicycle frame designed for urban use. The frame was modelled in SolidWorks and analysed using Finite Element Analysis (FEA) to validate its safety, durability, and ergonomic suitability. The key aim was to achieve an optimal balance between low weight and high structural strength while considering real-world riding conditions and manufacturability.
The design process began with initial hand sketches and ergonomic considerations in order to determine the ideal frame geometry. This was followed by parametric modelling in SolidWorks, where the bicycle frame was constructed with appropriate dimensions and joint configurations. Realistic load cases were then defined, including the rider’s body weight and operational forces acting on the structure. The model was prepared for analysis using meshing techniques with both 1D and 2D elements to accurately represent the structural behaviour. Boundary conditions were applied to constraint points such as the seat post and bottom bracket, which are typically subjected to high forces during use.
To evaluate structural performance, static linear FEA simulations were conducted using SolidWorks Simulation. A total load of 750 N was applied to represent combined rider and environmental forces. The Von Mises stress distribution showed that the maximum stress remained below the material’s yield strength, resulting in a factor of safety greater than 2. This confirmed that the design is structurally safe for typical riding conditions. Stress concentrations were primarily observed near the seat tube and bottom bracket area, leading to minor geometric modifications to reduce peak stress values. A comparative material study between steel and aluminium revealed that aluminium achieved better weight efficiency, although reinforcement was required in specific regions to maintain structural integrity.
Throughout this project, valuable engineering insights were gained regarding the influence of mesh quality, boundary condition accuracy and load assumptions on FEA results. The comparison between 1D and 2D simulations strengthened the understanding of modelling techniques in structural analysis, while the integration of analytical stress calculations supported and verified the FEA outcomes. The project also helped in understanding the practical link between theoretical engineering principles and design for manufacturability.
The final design provides a structurally safe foundation for future development. Potential improvements include exploring carbon fibre composites, conducting CFD aerodynamic analysis, creating a scaled 3D-printed prototype and performing real user testing to validate ergonomics and riding comfort. Overall, this project successfully combines engineering analysis with practical design decision-making and establishes a strong basis for further development of a lightweight and durable bike frame.