Duratec's Lightweight, Composite Carbon Fiber Street Racing Bicycle Frame Development
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
- Networks & Connectivity - Ethernet
Applicable Industries
- Life Sciences
- Plastics
Applicable Functions
- Procurement
- Product Research & Development
Use Cases
- Additive Manufacturing
- Manufacturing Process Simulation
About The Customer
Duratec Ltd., founded in 1992 by Milan Duchek, is a Czech company known for its innovative handmade bike frames. The company was established as a result of Duchek's enthusiasm for handmade bike parts. Duratec develops bike frames using both aluminium and composite materials, with a focus on individualized approach to their customers by providing unique bike parameters for rider satisfaction. The company's objective is to develop the best possible bike suited to customer expectations, with detailed attention provided to obtaining correct size, frame geometry and optimized seat positioning. Duratec also participates in collaborative efforts such as sponsorship of Czech Paralympic racer Jiri Jezek, a multiple gold-medal winner of four Paralympic Games.
The Challenge
Duratec, a Czech company known for its innovative handmade bike frames, was faced with the challenge of developing and optimizing a lightweight composite racing bike frame. The main objective was to create a world-class performance bike frame by minimizing mass while maintaining or increasing stiffness and strength. The bike frame, being the backbone of a reliable bike, had to be made with high-strength, high-modularity fibers laminated with the best resin. The challenge was further complicated by the need to comply with European standard EN 14781, which specifies performance and safety measures requirements. The Computer Aided Engineering (CAE) department at Advanced Engineering, Altair’s channel partner in the Czech Republic, had to optimize layer stacking and the number of plies necessary to meet all structural targets.
The Solution
To address the challenge, Duratec utilized the Altair HyperWorks suite for a three-stage optimization process. The model was created in Altair HyperMesh, optimized using Altair OptiStruct, and the results evaluated using Altair HyperView. The first stage involved Free-Size Optimization, where the optimum shape and location of each composite material layer were defined. The second stage was Size Optimization, where the optimum thickness of the ply-patches were determined. The final stage was Shuffle Optimization, which evaluated the possible stacking sequence of the composite layers and suggested the ideal order to meet the desired design characteristics. Duratec also used a unique manufacturing technology, OnePiece Technology - 100% monocoque, which allowed the entire frame to be produced as a whole, including tube connections, in one thermal process. This technology ensured the highest manufacturing precision and maximum processing quality.
Operational Impact
Quantitative Benefit
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