Bicycle Product Design Course

Lesson 1 • Bicycle Anatomy and Terminology

Introduces every major system and component using standardized industry terminology. Provides the shared vocabulary needed for all subsequent design work.

Lesson 2 • Bicycle Categories and Use Cases

Surveys road, mountain, urban, cargo, and specialty bicycle categories. Links category characteristics to rider needs and terrain requirements.

Lesson 3 • Design Principles and Constraints

Introduces core design principles—function, safety, aesthetics, and manufacturability. Shows how constraints shape every design decision from concept to production.

Lesson 1 • Human Body Measurement Fundamentals

Covers anthropometric measurement techniques relevant to bicycle sizing. Accurate body data is the starting point for all ergonomic design decisions.

Lesson 2 • Rider Posture and Riding Positions

Analyzes upright, aggressive, and neutral riding postures and their physiological effects. Connects posture choices to frame geometry and component selection.

Lesson 3 • Ergonomic Design for Diverse Riders

Addresses design adaptations for children, older adults, and riders with disabilities. Reinforces inclusive design as a professional standard.

Lesson 1 • Core Geometry Parameters

Defines stack, reach, head tube angle, seat tube angle, chainstay length, and wheelbase. Each parameter's effect on handling and fit is quantified.

Lesson 2 • Handling Dynamics and Stability

Explains how geometry parameters interact to produce steering feel, stability, and agility. Students predict handling behavior from a geometry sheet.

Lesson 3 • Frame Structural Analysis Basics

Introduces load paths, stress concentrations, and fatigue failure in bicycle frames. Provides the structural reasoning behind tube sizing and joint design.

Lesson 4 • Frame Standards and Interfaces

Covers bottom bracket shells, headset standards, dropout types, and axle specifications. Ensures designs are compatible with the broader component ecosystem.

Lesson 1 • Material Selection and Trade-off Analysis

Applies Ashby-style selection charts to bicycle frame design scenarios. Students produce a documented material selection rationale for a given project brief.

Lesson 2 • Carbon Fiber Composite Design

Introduces fiber orientation, layup schedules, and resin systems for carbon frames. Explains how composite design enables tunable stiffness and weight.

Lesson 3 • Aluminum and Titanium Alloys

Compares aluminum and titanium in terms of weight, corrosion resistance, and fabrication. Highlights trade-offs relevant to production volume and price point.

Lesson 4 • Steel and Chromoly Alloys

Examines high-tensile and chromoly steel grades used in bicycle frames. Covers weldability, tube butting, and the ride quality characteristics of steel.

Lesson 1 • Wheel Systems and Rolling Dynamics

Covers wheel building, spoke tension, rim profiles, and tire selection for rolling resistance. Integrates wheel specification into overall bicycle performance targets.

Lesson 2 • Suspension Design and Kinematics

Explains fork and rear suspension geometries, linkage types, and damper tuning principles. Connects suspension kinematics to frame geometry and rider feedback.

Lesson 3 • Braking Systems and Performance

Compares rim, disc, and hydraulic braking systems on modulation, weight, and heat management. Guides students in matching brake type to frame design and use case.

Lesson 4 • Drivetrain Systems and Gear Ratios

Covers chainring, cassette, derailleur, and internal hub systems with gear ratio calculations. Links drivetrain selection to terrain, rider power, and frame compatibility.

Lesson 1 • Surface Modeling for Carbon Frames

Applies Class-A surface techniques to model aerodynamic and organic carbon frame shapes. Bridges the gap between structural geometry and aesthetic form.

Lesson 2 • Finite Element Analysis Integration

Introduces FEA setup, meshing, load application, and result interpretation for frame models. Students validate structural designs before physical prototyping.

Lesson 3 • CAD Fundamentals for Frame Design

Introduces parametric modeling concepts using bicycle geometry as the design driver. Establishes the CAD workflow from sketch to solid model.

Lesson 4 • Modeling Tubes and Mitered Joints

Covers swept profiles, lofted surfaces, and miter cut generation for frame tubes. Accurate joint modeling is essential for downstream manufacturing and FEA.

Lesson 1 • Tube Preparation and Fixturing

Covers tube cutting, mitering, and jig setup for accurate frame assembly. Proper fixturing directly determines frame alignment and weld quality.

Lesson 2 • Carbon Fiber Layup and Curing

Guides students through mold preparation, prepreg layup, vacuum bagging, and autoclave curing. Covers defect identification and post-cure finishing.

Lesson 3 • Welding Techniques for Frame Building

Teaches TIG welding parameters, joint preparation, and distortion control for steel and aluminum. Weld quality is evaluated against structural and aesthetic standards.

Lesson 4 • Post-Processing and Surface Finishing

Covers alignment checks, reaming, facing, and surface preparation for paint or anodizing. Ensures the prototype meets dimensional and cosmetic specifications.

Lesson 1 • Design Validation and Release

Covers design verification plans, test reports, and regulatory compliance documentation. Prepares students to formally release a validated design for production.

Lesson 2 • Ride Quality and Handling Evaluation

Establishes subjective and objective methods for evaluating ride comfort, stiffness, and handling. Links rider feedback to specific design parameters for targeted iteration.

Lesson 3 • Failure Analysis and Root Cause Methods

Applies fractography, dye penetrant, and visual inspection to identify failure origins. Root cause analysis drives design corrections and prevents recurrence.

Lesson 4 • Structural Testing Standards and Methods

Introduces international fatigue and impact test standards for bicycle frames and forks. Students design test setups that replicate real-world loading conditions.