Redesigning The Mountain Bikes Rocker Arm Linkage Via Topology Optimization

Abstract

This project applies reverse engineering (RE) and topology optimization (TO) to redesign a mountain bike (MTB) rocker arm. The project aims to improve structural performance, reduce weight, and ensure optimal functionality below challenging restrictions. To capture the complex geometry of the current component with high accuracy, the Shining3D Combo Plus scanner is used to gather data. Then, to rebuild surfaces and repair flaws, the cloud data was processed in Geomagic Wrap, yielding a flawless, watertight polygonal model. Later, to verify dimensional precision and the smooth, permanent integration of the redesigned component into the bicycle frame, the prototype was imported into Autodesk Fusion 360 and converted into an entirely parametric CAD model. Altair Inspire was manipulated by the TO stage to apply a realistic 1200N load to reduce non-critical substructures, resulting in a lightweight structure with sufficient strength. The optimized aluminium design was validated through Finite Element Analysis (FEA), showing a maximum Von Mises stress of 120.806 MPa, a maximum displacement of 0.188 mm, and a safety factor of 3.0. The outcomes determined that another component is similarly weight-efficient and structurally robust under high working loads. The definitive stage of validation and manufacturability, utilizing the Bambu Lab X1 Carbon printer for optimized design via Fused Deposition Modelling (FDM) 3D printing. This established an even transition from simulation-driven redesign to physical prototyping, with printed models confirming the geometric accuracy and assembly tolerances of the redesigned part, indicating that the multifaceted, optimized topology will likely be manufactured and assembled into a useful product.