Case Study: Duratec (Czech bike manufacturer) achieves 28% weight reduction in composite racing frame with Altair HyperWorks

Development of a Lightweight, Composite Carbon Fiber Street Racing Bicycle Frame

Duratec, a Czech maker of handmade racing bike frames, faced the challenge of developing a lightweight carbon-fiber composite frame that met strict strength and stiffness requirements (EN 14781) while minimizing mass. To address complex composite tuning—fiber angle, ply sequence and number of plies—Duratec worked with Altair (through channel partner Advanced Engineering) using the Altair HyperWorks suite, including Altair HyperMesh, Altair OptiStruct and Altair HyperView.

Using a three-stage optimization workflow (free-size, size and shuffle) in Altair HyperWorks and selecting high-strength T700 UD material, Altair’s tools guided laminate stacking and thickness decisions and validated multiple load cases. The result was a monocoque PHANTOM frame manufactured with AFCF lay-up that met all stiffness and strength targets and reduced the ready-to-buy frame weight from 980 g to 700 g (590 g unpainted)—a 28% mass reduction—while preserving or improving performance.

Duratec

Milan Duchek

Founder and Owner