We are a team of keen engineering students from Sheffield Hallam University, with a personal passion for mountain biking and innovative technologies in this field. We aim to design, manufacture, and test a unique full-suspension mountain bike.
We began with in-depth research into bike kinematics and geometry, understanding how these factors influence performance across varying terrains. This taught us a great deal about how and why our bikes react to various inputs and changes in terrain. Using our theoretical knowledge, we used specialist software, Linkage, to develop a 2D model of a bike. This model optimises the kinematic and geometry we believe to be most important for mountain biking.
To manufacture our design, we chose a bonded carbon tube and lug construction method. This manufacturing approach balances performance and feasibility, considering the tools and machinery available to us at the university while also being a tested method of prototyping within the industry. Carbon tubing provides the opportunity to engineer custom layups and shapes, delivering strength and compliance tailored to specific areas of the frame. Metal lugs, on the other hand, offer precise points of connection, enabling us to achieve the complex angles and tolerances required for our suspension system.
Our project is more than just a passion project, it is a hands-on engineering challenge while applying the theoretical principles we study in class. The project will also improve our creativity, teamwork, and problem-solving. This process will enhance our technical capabilities in areas such as materials science, structural analysis, and advanced manufacturing techniques. Additionally, testing our bike in real-world conditions will provide valuable data to assess the effectiveness of our design, enabling future iterations to be made and improved upon.
We hope this project continues past our time at university and is improved upon by future students. By documenting our process and outcomes, we hope to create a resource that future students can build upon. Our goal is to inspire ongoing experimentation and improvement, ensuring that this initiative contributes not only to our personal growth but also to the academic and professional community at large.
We are incredibly excited about the future of this project and the skills it will allow us to develop.
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