Client:
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Nine Gs
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Project:
Aerospace-Grade Generative Design Applied to High-Performance Sports Equipment
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​Objective:
​Redesign a bicycle handlebar stem for racing applications using aerospace-inspired structural optimization methods to improve strength-to-weight performance, reduce material waste, and use conventional carbon fiber or CNC-machined aluminum manufacturing.
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Baseline Challenge:
Conventional stems are overbuilt to ensure safety and rigidity, often resulting in excess material, weight penalties, and suboptimal load distribution, especially under torsional and impact loads from road terrain or sprinting forces. The goal was to achieve equivalent strength and stiffness with minimal weight while maintaining manufacturability using existing carbon layup or CNC methods.
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DuroWorks Approach:
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We applied a hybrid Generative Design and FEA workflow integrating:
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Topology Optimization based on real-world loading and safety constraints.
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Design-to-manufacture conversion of the organic shape into a prismatic form.
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Stress & Stiffness Analysis comparing original and optimized versions.
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Geometry Tailoring for both CNC-machined aluminum and carbon layup paths.
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​Results:
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Improved Aesthetics and Tangible Performance Gains
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21% Weight Reduction
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Improved stiffness in torsion and vertical load cases
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High safety margins in critical zones for fatigue resistance
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Fully manufacturable design for carbon or aluminum
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Unique aesthetic showcasing function-driven design
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Key Innovation:
​​This case study shows how aerospace-level engineering methods can be directly applied to consumer-facing performance products. By combining GD with structural analysis and a practical design-for-manufacture process, DuroWorks delivered a lightweight, production-ready racing stem that reflects true structural efficiency, not just visual innovation.
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Unlike traditional GD approaches focused only on Additive Manufacturing, the DuroWorks method delivers near-final geometries optimized for real-world production. This approach unlocks the benefits of GD while keeping fabrication simple, scalable, and affordable.​​​
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Conclusion:
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High-performance sports equipment, especially safety-critical components, benefits from the same design rigor and innovation used in aircraft development. Using conventional materials and manufacturing processes, the DuroWorks process empowers product teams with superior engineering outcomes.