Springfree Trampoline Cleat Optimization Using Abaqus FEA

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Springfree Trampoline Cleat Optimization Using Abaqus FEA

Case study showing how Matrix Applied Computing used Abaqus FEA and topology optimization to redesign a high-volume polypropylene cleat for improved strength without added cost.

Published

June 4, 2026

Read time

3 min read

Source

Matrix Applied Computing applied nonlinear FEA in Abaqus and SIMULIA ATOM topology optimization to redesign the fiberglass-reinforced cleat that connects support rods to the mat on Springfree trampolines. The project incorporated physical test data, Moldflow fiber orientation results, and manufacturing constraints to increase ultimate load capacity while reducing material usage. The optimized four-rib geometry is now in production and under evaluation for future models.

Key takeaways

Abaqus FEA combined with physical testing validated cleat geometry changes that raised ultimate load without added material cost

Moldflow fiber orientation and residual stress data were imported into Abaqus models to improve simulation accuracy

SIMULIA ATOM topology optimization identified a third rib and reduced CAD iteration time compared with manual redesign

Collaboration with the moldmaker ensured the final design remained manufacturable at 2.5 million units per year

A new four-rib variant is being evaluated for the next trampoline generation

Market overview

SCR methodology note

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