Simulation's Role in Developing the Lightweight, All Titanium Brompton

Yan Pugh-Jones, Engineering Director, and Steven Harry, Lead Structural Engineer at Brompton Bicycle present at the UK Altair Technology Conference 2022.

Every millimetre of the classic folding Brompton Bicycle has been reinvented to create our lightest bike ever, the T Line. The product of three years of limitless thinking, research and development, the T Line weighs just 7.45kg in its lightest form compared to 11kg for the traditional steel model.

To deliver this incredible weight saving, advanced engineering materials and methods were employed, with over 150 brand new lightweight components developed specifically for this bike. The frameset is made entirely from titanium, finished off with carbon fibre forks, handlebars, cranks and seatpost, delivering the required reduction in weight while retaining the strength and durability expected of a hard-wearing city bike.

Using Finite Element analysis and topology optimisation methods throughout the development of the T Line allowed us to use the minimum possible amount of material while maintaining targets for stiffness and strength. Utilising Altair’s OptiStruct, SimSolid and Inspire software packages enabled us to push the boundaries of what was possible, to deliver the most advanced evolution of the iconic Brompton folding bicycle to date.