CFRP Material characterization & laminate development for a Bicycle Cockpit
Problem statement
Canyon, a high-performance bicycle company, needs a way to accurately determine the material properties of the CFRP (Carbon Fiber Reinforced Polymer) composites used in their structural components. These properties are currently unknown, limiting their ability to design lightweight, durable, and optimized frames and assemblies. Canyon is a highly innovative company with a customer appeal to athletes who are looking for a light yet strong bike for top performance. CFRP is the chosen material due to its material properties; according to sources like Zwick Roell, Carbon Fiber can be five times stronger than steel while being a fraction of the weight, but its orthotropic properties make it possible to create higher stiffness in some places and more compliance in others. In the competitive cycling industry, where weight, strength, and performance are critical, relying on generic or assumed material data can lead to overengineered parts, wasted material, or even structural failures. With athletes depending on Canyon’s products for both peak performance and personal safety, there is a strong need to ensure that new designs are backed by accurate, experimentally validated inputs. To develop next-generation carbon fiber bicycle components and ensure the safety of their consumers, the company must validate their materials and confirm their finite element analysis (FEA) models to reflect real-world behavior. This project will address that need by experimentally determining the material properties of the CFRP used, validating those properties through FEA using test setups, and applying the results to the design and optimization of a real bicycle component – the CP0036 cockpit structure. Laminate thickness, stacking sequence, and ply orientation will be tailored to meet known loading conditions and performance requirements. By combining experimental mechanics, FEA modeling, and composite design optimization, this project gives students a hands-on opportunity to contribute directly to innovation in the cycling industry.
Team members
Fiona King – communicator
Jenna Caruso – admin
Jacob Hayes – accountant
Logan Measner – facilitator
Client
Philipp Bauer
Canyon Bicycles