Independent engineering · Bicycle frame
Carbon-Al Bike
A staged bicycle-frame development project moving from polycarbonate prototypes to aluminum tubes, PPA-CF joints, and full-frame assembly.
Project record
What the work demonstrates.
Carbon-Al Bike is the central project in this portfolio because it brings structural design, material choices, additive manufacturing, and bicycle-system integration into one physical build.
The work is unfinished but already has concrete outcomes. Each stage records a change in material or construction strategy, rather than presenting the current frame as a single isolated result.
Translate individual structural components into a frame whose geometry, joints, manufacturing decisions, and bicycle systems work together.
Development record
Stages, iterations, and evidence.
- 01
Stage 1
Polycarbonate prototype
The first stage established an early physical reference for the frame concept. Photographs, geometry decisions, and lessons from this version are reserved for the full project record.
- 02
Stage 2
Aluminum + PPA-CF
The second stage combined aluminum members with PPA-CF printed joints. This stage includes the topology-optimized seat-joint work and the developing bottom-bracket design.
- 03
Stage 3 · Current
Frame assembly
The present stage brings the components into a complete frame and shifts the design problem toward geometry, interfaces, fit, and compatibility with the rest of the bicycle.
Active questions
What the next evidence needs to answer.
- 01How should the joint geometry carry load while remaining manufacturable?
- 02How do frame geometry and component interfaces affect the complete bicycle?
- 03Which decisions need physical validation before the frame can progress?