CD-02 Campbell Downs
Project 02 · CAD + Analysis

Bike Horn Mount Optimization

Parametric modeling and optimization of a lightweight Nylon 6/10 accessory bracket.

Parametric CAD Topology Mass reduction
Final optimized bike horn mount geometry
Final optimized geometry after parametric screening and topology-guided material removal.

Rebuilt a non-robust baseline model into a simplified, optimization-ready mount, then evaluated geometry changes against mass and minimum factor of safety.

0.2055 NHorn load
Nylon 6/10Material
270Design scenarios

Baseline to parametric design

Variables studied: bridge width, length, and fillet radius.

Baseline bike horn mount CAD model
Baseline design.
Selected parametric bike horn mount
Selected parametric design.
Scatter plot of mass versus minimum factor of safety for 270 scenarios
Mass vs. minimum factor of safety across all 270 scenarios.

Topology-informed redesign

Moving from parametric optimization to targeted material removal.

Topology optimization result showing low-stress removal regions
Topology result: low-stress removal regions.
Final optimized mount
Final optimized geometry.
Final static FEA study of the optimized mount
Final static study.

≈30%

Mass reduction from the selected parametric design. Final factor of safety remained above 100.

Engineering takeaway

Simplify an unstable CAD model, define meaningful parameters, evaluate design-space tradeoffs, then use topology results to guide final geometry.