Composite Layup Optimization Design for Bicycle Frames｜OptiStruct

【 Background 】

       Next-generation bicycle frames continue advancing toward being lighter and stronger, making composite materials the natural choice. However, composite layup design involves numerous parameters such as ply coverage, orientation, thickness, and stacking sequence. Combined with manufacturing constraints and extensive testing requirements, product development often becomes extremely challenging.

【 Solution 】

       Richin’s solution: Altair OptiStruct provides a unique and well-structured optimization workflow. Following this process, designers can efficiently determine key parameters such as ply coverage, thickness, and stacking sequence.

【 Highlights 】

1. Flexible definition of various manufacturing parameters, such as preset prepreg size and thickness, ensuring ply patterns remain practical and consistent with real manufacturing constraints.

2. Ability to create “sublaminate groups” that must appear at the inner or outer layers while maintaining sequence integrity.

3. Prediction and correction of fiber angle deviation introduced during manufacturing.

4. Built-in ply shape unfolding tools allow exporting ply patterns for precise laser-cutting.

【 Results 】

1. 18% weight reduction

2. Meets structural strength requirements

3. 70% reduction in development time

4. 85% reduction in testing cost