Trek Bicycles Simulation Case Study: Abaqus FEA for Bike Performance
Case study showing how Trek expanded Abaqus FEA and True-Load to capture real-world loads from professional riders and improve lab testing.
Trek Bicycles used SIMULIA Abaqus finite element analysis combined with True-Load to measure extreme loads on mountain bikes during professional stunts. Engineers instrumented frames with strain gauges on private test trails, then back-calculated accurate load histories that matched measured strains within 2%. Results revealed higher loads and different rear-end load shares than standard lab tests, enabling refined design targets and fewer physical prototypes.
Abaqus FEA plus True-Load reduced physical make-and-break cycles by predicting stiffness and weight earlier.
Field data from pro riders showed loads exceeding standard lab tests and model-specific rear load distributions.
Strain-gauge placement guided by simulation produced load histories accurate to within 2% of measured values.
Process now supports load-case development for additional bike platforms across Trek engineering teams.
Integration of CATIA design data with Abaqus models enabled rapid extension from composites to full-suspension frames.
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