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The goal of this research is to design, analyze, and manufacture a carbon fibre bicycle stem that maximizes the use of carbon fibre composites. The stem is a part of the bicycle that connects the handlebar to the fork. The design is difficult due to the small size and complex geometry of the part, thus not obvious to conceive with a standard composite manufacturing approach. A novel approach using an inner bladder resin transfer moulding (RTM) technique is used to manufacture the bicycle stem. The design of the moulds incorporates some efficient devices to facilitate various steps in the manufacturing process. The resulting design is successful in terms of weight, stiffness, strength, and aesthetic properties. The developed technique used in this project can be applied as a possible solution to the design and fabrication of small, complex, hollow composite parts.

Design of a Carbon Fiber Bicycle Stem using a Novel Internal Bladder Resin Transfer Molding Technique