During my senior year at Cal Poly, I designed and fabricated a full suspension mountain bike with the help of the Bike Builders Club.

Goals

• Design and fabricate a mountain bike for a 6'6" rider (myself)
• Integrate off the shelf components
• Optimize handling characteristics with Patterson Control Model (PCM)

Methods

• Simulated suspension in Linkage X3 software
• Modeled assembly in Fusion 360 to confirm clearances and generate drawings
• Analyzed shock mounting tab in Abaqus FEA
• Fabricated welding fixture on CNC mill

Results

• Frame is within tolerance, including critical areas like the press fit bearings
• TIG welded joints are consistent and have held up to 300+ miles of real world riding with no signs of failure
• The bike handles as expected, matching the predictions of the PCM and Linkage models

Linkage X3 model of the 4-bar suspension

Abaqus FEA results for the shock tab, which resists up to 1100 lbs of force

Frame mounted to the fixture plate prior to welding main pivot

Finished front triangle with primer (white) bolted to repurposed rear triangle from Vitus Mythique (black)