Design and manufacturing of a carbon fiber subframe for electric superbike

Abstract

The objective of this thesis was the design and manufacturing process of a carbon fiber subframe for an electric superbike JHC Ukkonen. The goal was to create a light-weight and manufacturable subframe that meets mechanical and functional requirements. The development process included a review of composite material behavior, fiber orientation and existing research on motorcycle subframes. A CAD model was created based on a C-profile concept, followed by finite element analysis to estimate structural performance. The study also considered design-for-manufacturing constraints and mold-making procedures. Subframe prototype was manufactured from prepreg carbon fiber using internal equipment of JHC.