Frame Team

About the Team

The Frame team is responsible for the entire physical structure of the SD² bike. They are taking the finalized geometry through all stages of development, from research and design to manufacturing and testing. Their work ensures the frame's performance, durability, and suitability for competitive downhill racing, forming the foundation upon which the rest of the bike is built. 

Overview

The main objective for our first prototype frame is to create a reliable and measurable frame which will be a metric for future iterations. Currently, we are constructing the front triangle from Renolds steel, and we are researching the possibility of a composite rear triangle.

Details

The SD² project encompasses five key phases which drive our team's actions:

1. Design Phase

Finalising frame geometry, including suspension kinematics, and designing all frame components (e.g., front triangle, rear triangle, linkages). This includes CAD modelling, FEA (Finite Element Analysis) for stress and strength optimisation, and design for manufacturability. Responsibility for the design of the adjustable geometry features. 

2. Manufacturing Phase

Overseeing the manufacturing process of the frame, which involves working with external manufacturer - Eighteen Bikes who will be providing manufacture of welded components and acting as the team's industry mentor. As well as the team's in house manufacturing of certain components. This includes quality control checks, ensuring precise tolerances, and potentially hands-on involvement in fabrication (e.g. machining, composite layup). 

3. Lab Testing Phase

Conducting rigorous lab tests on the frame to validate its strength, durability, and fatigue resistance. This involves static load testing, impact testing, and fatigue testing. The team will analyse the test data and make any necessary design modifications. 

4. Ride Testing Phase

Working with riders to test the frame's performance on the trail. This includes evaluating the suspension performance, handling characteristics, and adjustability features. The team will gather rider feedback and make further refinements to the frame design. They will also be testing different geometry configurations using the adjustable features. 

5. Race Phase

Supporting the race team by ensuring the frame is properly maintained and set up for each race. Involved in making quick adjustments to the frame geometry based on track conditions. Post-race analysis of frame performance and any damage will inform future design iterations.