Structural design of a composite bicycle fork

•Case study about composite bicycle fork design.•Special requirements for a Student Team project.•FE model to evaluate stiffness, strength and potential failure modes.•Comparison of two manufacturing approaches.•FE model stiffness validation on the manufactured fork.

Despite the wide literature on the mechanical behaviour of carbon/epoxy composites, it is rare to find practical methodological approaches in finite element design of structural components made by laminate layup. Through the case study of a special bicycle fork needed in a Student Team prototype, this paper proposes a simplified methodology as starting point for educational and manufacturing purposes. In order to compare two manufacturing solutions in terms of stiffness, strength and failure mode, a numerical model was implemented. Since the project requirements imposed to avoid standard destructive testing, the model validation was based on a posteriori linear stiffness comparison with the manufactured component. The slight discrepancies between experimental and numerical results were discussed in order to check their origin and to assess the reliability of the model. The overall methodology, even if complain with only a part of the safety standard requirements, shows to be reliable enough and can be the basis for further extension and refinement.