College of Engineering
Mechanical Engineering Department
BS in Mechanical Engineering
Sarah T. Harding
Cal Poly Bike Builders (CPBB) is a student club at Cal Poly helping students design and fabricate their own bicycles. Currently, club members build rigid frames and mountain bikes with only front-suspension–commonly referred to as a “hardtail”. As more students join the club, interest grows in building full-suspension mountain bikes (FSMTB). Designing and manufacturing a mountain bike rear-suspension system requires a diverse skillset and a substantial time commitment. As a result, individual efforts building FSMTB have proven unsuccessful. The scope of this project is to develop a defined method and necessary tools such that all CPBB members can efficiently build a FSMTB rear-suspension system. Initial background research drove engineering specifications developed from customer needs and wants. These parameters influenced initial concept development and evaluation. Detailed analysis then determined which concept design would become the final design. A manufacturing plan details the necessary tooling and potential challenges during the build process. A confirmation prototype of the final design assesses the manufacturing plan as well as the final designs. Testing validated the final design against engineering specifications. Project management details the project organization process, potential issues, and major deliverables. Final concluding remarks detail overall reflections, remarks, and future recommendations.