Case Study: Guerrilla Gravity achieves faster development and 300% more impact-resistant, lightweight Revved Carbon frames with Altair OptiStruct

Guerrilla Gravity Improves Manufacturing Method for the Most Durable and Lightweight, High-performance Bikes

Guerrilla Gravity, a Denver-based mountain bike manufacturer, developed Revved Carbon Technology to deliver lightweight, high-performance frames that are unusually durable. Their challenge was scaling production and pioneering a new material and manufacturing method with no roadmap, putting launch schedules at risk. To address this, Guerrilla Gravity partnered with Altair and used Altair OptiStruct™ early in the design process.

Altair used OptiStruct’s topology and orthotropic optimization to guide ply placement across multiple load cases, accelerating design decisions, reducing testing unknowns, and enabling first-pass success on ASTM tests. The Altair-enabled approach shortened development by an estimated 3–4 months, helped Guerrilla Gravity achieve frames that are 300% more impact resistant while maintaining weight and stiffness, and—combined with automated fiber placement—cut labor times by over 80%, allowing the company to hit launch and financial targets.

Guerrilla Gravity

Will Montague

Co-Founder