Manufacturing Considerations and Bill Of Materials Urbanspeed bicycle
Based around manufacturing quantities of 1,000 units, 5,000 units and 10,000 units
This booklet was put together to summarise the real world realisation of the Urbanspeed Bicycle. In the latter stages of the design process, my concept needed to enter a new phase of design where detail development was influenced by structural analysis, component minimisation and sourcing, manufacturing design and cost review.
Structural Analysis
Testing my design with 4000N worth of force and using a range of materials allowed me to determine where gussets and thickness need to be placed. My final design can be manufactured from 6061 Aluminium, a materials commonplace in the bicycle industry.
Straight Tubing
Single Bent Piece Of Tubing
Stamped Dropouts
Cast Section
Component Design
Straight Tubing
After the structural analysis was conducted, the pieces were designed to have the minimum cost whilst maintaining this integrity. The cast section needed particular attention as it acted as a key structural member.
Gusset Plate
Single Bent Piece
Cross Tubing
46.
Bill Of Materials 43.
45. 48.
59.
61. 33. 54.
62.
39.
56. 57. 37.
60.
41.
63. 40.
53.
1.
2.
4.
7.
47.
43.
46.
59. 52.
5.
9.
13.
12.
27.
Part Name
Part Number
Part Section
Quantity
Material
Mat Finish
Size (wxlxh)
Tyres
1.
Wheels
2
Rubber
Matte
Rims
2.
Wheels
2
6061 Aluminium
Matte
Rim Components (Misc)
3.
Wheels
Spokes
4.
Wheels
72
6061 Aluminium
Matte
N/A
N/A
2.70 g/cm³
>5gm
Front Hub
5.
Wheels
1
Steel
Polished
120mm
N/A
N/A
N/A
Rear Hub
6.
Wheels
1
Steel
Polished
130mm
N/A
N/A
N/A
Front Axle Spacer
7.
Wheels
2
Aluminium
Aluminium
5mm ID & Length
10gm
2.70 g/cm³
5gm
Front Axle
8.
Wheels
1
Steel
Polished
135mm
N/A
N/A
N/A
Fenders
9.
Accessories - Fender
2
Polypropylene
Matte
70.05cm³
0.9383 g/cm³
140gm
Fender Components
10.
440mm X 100mm X 44mm
Bolt
11.
Accessories - Fender
2
Alloy Steel
Polished
8mm X 25mm
N/A
2.70 g/cm³
>5gm
Nut
12.
Accessories - Fender
2
Alloy Steel
Polished
M4 X 4mm
N/A
2.70 g/cm³
>5gm
13.
Accessories - Fender
4
Alloy Steel
Polished
8mm X 10mm
N/A
2.70 g/cm³
>5gm
Front Rim Brake
14.
Brakes
1
Matte
Matte
N/A
N/A
N/A
N/A
Lever
15.
Brakes
1
Aluminium
Polished
N/A
N/A
N/A
N/A
16.
Brakes
2
Aluminium
Matte
N/A
N/A
N/A
N/A
Brakes
1
Aluminium
Matte
N/A
N/A
N/A
N/A
18.
Brakes
2
Aluminium
Polished
N/A
N/A
N/A
N/A
19.
Brakes
2
Rubber
Polished
30mm X 5mm
N/A
N/A
N/A
Washer
Lever Bracket
Cable
Rim Frames
Rim Brake Pads
17.
Volume
Material Density
Weight
20” X 1.75”
N/A
200gm
20” X 1.75”
2.70 g/cm³
1200gm
2.70 g/cm³
6061 Aluminium
MFG Process
Nominal Wall Thickness
Tooling/ Setup Costs
Production Cost
STD Component STD Component
N/A N/A
N/A N/A
N/A N/A
N/A N/A
STD Component
N/A
N/A
N/A
N/A
STD Component
N/A
N/A
N/A
STD Component
N/A
N/A
N/A
STD Component
N/A
N/A
STD Component
N/A
N/A
STD Component
N/A N/A
Section Assembly Time
Part Supplier
Amortized Part Cost/ 1,000
Amortized Part Cost/ 5,000
Amortized Part Cost/ 10,000 $.80
Guangzong Zhengyu
STD Part Cost:
$4.00
$2.70
$1.20
Guangzong Zhengyu
N/A
STD Part Cost:
$3.30
$2.45
$2.30
Shimano
N/A
STD Part Cost:
$14.00
$7.90
$7.02
Shimano
$.70 each
$.70 each
$.70 each
McMaster Carr
$2.00
$1.00
$1.00
Ningbo Maoying
1,000 Parts
5,000 Parts
10,000 Parts
$24.75
$14.40
$12.39
STD Part Cost:
N/A N/A
STD Part Cost: Total Section Cost:
$1.20
$.90
STD Component Supplier
Injection Moulded
4mm
$8,945
$2,935
.1 Hours
$11.40 per part
$2.55 per part
$1.10 per part
STD Component
N/A
N/A
N/A
N/A
$6.53 per 25
$6.53 per 25
$6.53 per 25
McMaster Carr
STD Component
N/A
N/A
N/A
N/A
$3.00 per 50
$3.00 per 50
$3.00 per 50
McMaster Carr
STD Component
N/A
N/A
N/A
N/A
$4.50 per 100
$4.50 per 100
$4.50 per 100
McMaster Carr
1,000 Parts
5,000 Parts
10,000 Parts
$12.43
$3.18
$1.36
STD Part Cost:
$3.00
$2.12
$1.89
Ningbo Maoying
STD Part Cost:
$1.40
$1.00
$1.00
Ningbo Maoying
1,000 Parts
5,000 Parts
10,000 Parts
$4.40
$3.12
$2.89
STD Part Cost: Total Section Cost:
STD Component
N/A
N/A
N/A
N/A
STD Component
N/A
N/A
N/A
N/A
STD Component
N/A
N/A
N/A
N/A
STD Component
N/A
N/A
N/A
N/A
STD Component
N/A
N/A
N/A
N/A
STD Component
N/A
N/A
N/A
N/A
Total Section Cost:
57.
58. 11. 10.
56.
28.
24. 23. 21.
20. 22.
Bill Of Materials
47.
46.
44.
45.
43.
48.
Part Name
Part Number
Part Section
Quantity
Material
Mat Finish
Size (wxlxh)
Volume
Material Density
Weight
Belt
20.
Drivetrain
1
Carbon Kevlar
Matte
113t x 1273mm
N/A
N/A
N/A
Front Sprocket
21.
Drivetrain
1
Aluminium
Matte
130mm x 60t
N/A
N/A
N/A
Rear Sprocket
22.
Drivetrain
1
Aluminium
Matte
Hyperglide 20t
N/A
N/A
N/A
Spider
23.
Drivetrain
5
6061 Aluminium
Matte
N/A
N/A
N/A
N/A
24.
Drivetrain
1
Alloy Steel
Polished
5mm Socket X 6mm
N/A
N/A
N/A
Crank
25.
Drivetrain
1
Aluminium
Polished
N/A
N/A
N/A
N/A
Crank Components
26.
Drivetrain
1
Aluminium
Polished
N/A
N/A
N/A
N/A
Rear Axle
27.
Drivetrain
1
Steel
Polished
125mm
N/A
N/A
N/A
Pedal & Pedal Mechanism
28.
Drivetrain
2
ABS
Polished
120mm X 80mm
1.02 g/cm³
65gm
Dropout X2 (L and R)
29.
Drivetrain
2
Steel
Matte
40mm X 40mm X 5mm
N/A
7.90 g/cm³
N/A
Tensioner
30.
Drivetrain
4
Steel
Matte
50mm
N/A
N/A
N/A
Slide Plate
31.
Drivetrain
4
Steel
Polished
N/A
N/A
N/A
Axle Nuts
32.
Drivetrain
2
Steel
Matte
20mm X 40mm X 4mm M12 X 8mm
N/A
7.90 g/cm³
N/A
Bolt
33.
Accessories - Rack
6
Alloy Steel
Polished
M8 X 40mm
N/A
7.90 g/cm³
N/A
Nut
34.
Accessories - Rack
6
Alloy Steel
Polished
M8
N/A
7.90 g/cm³
N/A
Washers
35.
Accessories - Rack
12
Alloy Steel
Polished
20mm X 2mm
N/A
7.90 g/cm³
N/A
Spacer
36.
Accessories - Rack
4
Rubber
Matte
M8 X 2mm
N/A
2.679 g/cm³
N/A
Front Bracket
37.
Accessories - Rack
1
Steel
Polished
N/A
2.35 cm³
2.679 g/cm³
10gm
Rear Bracket
38.
Accessories - Rack
1
Steel
Polished
N/A
0.74 cm³
2.679 g/cm³
5gm
Rack Clip
39.
Accessories - Rack
1
Polypropylene
Matte
35.6 cm³
0.9383 g/cm³
50gm
Rack Support
40.
Accessories - Rack
1
Aluminium 6061 - T6
Semi Gloss Paint
170mm X 47mm X 12.5mm 16mm - 2mm
35.1 cm³
2.70 g/cm³
100gm
Rack Bed
41.
Accessories - Rack
2
Aluminium 6061 - T6
Semi Gloss Paint
16mm - 2mm
50 cm³
2.70 g/cm³
200gm
Rack Dropout Plate
42.
Accessories - Rack
2
Aluminium 6061 - T6
Polished
25mm X 10mm X 5mm
1.25 g/cm³
2.70 g/cm³
5gm
Spider Bolts
Rack Components
MFG Process
Nominal Wall Thickness
Tooling/ Setup Costs
Production Cost
N/A
N/A
STD Component
N/A
N/A
STD Component
N/A
STD Component
Section Assembly Time
Part Supplier
Amortized Part Cost/ 1,000
Amortized Part Cost/ 5,000
Amortized Part Cost/ 10,000
STD Component Supplier
$1.42
Gates Belt Systems
N/A
STD Part Cost:
N/A
N/A
STD Part Cost:
$8.40
$3.20
$2.64
Gates Belt Systems
N/A
N/A
N/A
STD Part Cost:
$5.40
$3.50
$2.90
Gates Belt Systems
N/A
N/A
N/A
.25
STD Component
N/A
N/A
N/A
N/A
STD Part Cost: STD Part Cost:
STD Component
N/A
N/A
N/A
.25
STD Part Cost:
STD Component
N/A
N/A
N/A
N/A
STD Part Cost:
STD Component
N/A
N/A
N/A
N/A
STD Part Cost:
Injection Moulded
5mm
$10,633
$631
Metal Stamping
3mm
$ 1,834
STD Component
N/A
Metal Stamping STD Component
STD Component
N/A
$3.00
$1.74
Shimano $4.58 per 50
$4.58 per 50
$4.58 per 50
Shimano
$10.00
$8.03
$6.50
Shimano Shimano
$1.00
$1.00
$1.00
.125
$2.04
$1.40
$1.14
$ 1,004
5 min
$ 1.10
$ .95
$ .80
N/A
N/A
N/A
$2.12
$1.90
$1.24
3.5mm
$ 1.034
$ 432
> 1min
$ .42
$ .40
$ .40
N/A
N/A
N/A
N/A
$4.15 per 25
$4.15 per 25
$4.15 per 25
1,000 Parts
5,000 Parts
10,000 Parts
$33.80
$17.37
$14.19
Total Section Cost:
Ningbo Maoying
McMaster Carr
McMaster Carr
STD Component
N/A
N/A
N/A
N/A
$6.53 per 25
$6.53 per 25
$6.53 per 25
McMaster Carr
STD Component
N/A
N/A
N/A
N/A
$4.26 per 25
$4.26 per 25
$4.26 per 25
McMaster Carr
STD Component
N/A
N/A
N/A
N/A
$2.05 per 100
$2.05 per 100
$2.05 per 100
McMaster Carr
STD Component
N/A
N/A
N/A
N/A
$1.10 each
$1.10 each
$1.10 each
McMaster Carr
Cold Forming
2mm
$1,600
$2,130
N/A
$ 1.40
$ 1.40
$ 1.40
Cold Forming
2mm
$2,340
$2,650
N/A
$ 2.20
$ 2.20
$ 1.85
Injection Moulded
2mm
$4,580
$1,895
N/A
N/A
$1.50
$1.01
Bent Tubing/Weld
2mm
$ 1,300
$ 1,156
1 min
$ 2.40
$ 1.03
$ .75
Bent Tubing/Weld
2mm
$ 2,000
$ 1,379
1 min
$ 5.60
$ 3.80
$ 2.80
Metal Stamping
5mm
$ 1,240
$ 600
> 1min
$ .50
$ .42
$ .36
1,000 Parts
5,000 Parts
10,000 Parts
$16.55
$7.70
$6.48
Total Section Cost:
Bill Of Materials 39.
33. 34. 41. 25.
35.
26.
40.
42.
8.
58. 6.
21.
22.
20.
32.
31. 3.
30. 29.
Part Name
Part Number
Part Section
Quantity
43.
Steering
1
Material
Mat Finish
Size (wxlxh)
Volume
Material Density
Weight
Steel 302
Matte
18cm³
7.40 g/cm³
50gm
>3cm³
0.94 g/cm³
>10gm
Stem Bush
44.
Steering
1
Nylon 6
Matte
75mm X 50mm X 20mm 12mm X 25mm
Stem Bolts
45.
Steering
2
Alloy Steel
Polished
6mm X 30mm
N/A
N/A
N/A
Bars
46.
Steering
1
Aluminium
Polished
550mm X 22mm
N/A
2.70 g/cm³
N/A
Grips X 2
47.
Steering
2
Rubber
Matte
80mm X 25mm
4cm³
0.64 g/cm³
50gm
Cam Clamp (Headtube)
48.
Steering
1
Aluminium
Matte
N/A
N/A
2.679 g/cm³
50gm
Cam Clamp (seatpost)
49.
Seat
2
Aluminium
Matte
N/A
N/A
2.679 g/cm³
50gm
Seat post Outer
50.
Seat
1
Aluminium 6061 - T6
Semi Gloss Paint
28mm - 3mm
75.8 cm³
2.70 g/cm³
200gm
Seat post Inner
51.
Seat
1
Aluminium 6061 - T6
Semi Gloss Paint
21.5mm - 2mm
25.1 cm³
2.70 g/cm³
100gm
Saddle
52.
Seat
1
Foam/Canvas
Matte
140mm X 100mm
N/A
N/A
N/A
Fork/Stay Tube
53.
Frame
1
Aluminium 6061 - T6
Semi Gloss Paint
25.4mm - 2mm
90.6 cm³
2.70 g/cm³
280gm
Frame Tube
54.
Frame
1
Aluminium 6061 - T6
Semi Gloss Paint
25.4mm - 2mm
220.6 cm³
2.70 g/cm³
800gm
Frame – Cross
55.
Frame
1
Aluminium 6061 - T6
Matte
25.4mm - 2mm
10.6 cm³
2.70 g/cm³
60gm
Frame Cast
56.
Frame
1
Aluminium
Matte
146.129cm³
2.679 g/cm³
400gm
Frame Bush
57.
Frame
1
Nylon
Matte
22.0 cm³
0.94 g/cm³
30gm
Frame Cam Clamps
58.
Frame
2
Aluminium
Matte
83.2mm X 123.5mm X 145mm 56mm X 120mm X 26mm N/A
N/A
7.90 g/cm³
N/A
Head tube
59.
Frame
1
Aluminium 6061 - T6
Polished
25.4mm - 2mm
57.7 cm³
2.679 g/cm³
200gm
Head tube Inner
60.
Frame
1
Aluminium 6061 - T6
Raw
21mm - 2mm
26.8 cm³
2.679 g/cm³
60gm
Head tube case
61.
Frame
1
Aluminium 6061 - T6
Semi Gloss Paint
38mm - 2mm
32.0 cm³
2.679 g/cm³
100gm
Headset
62.
Frame
1
Aluminium 6061
Matte
N/A
2.679 g/cm³
N/A
Fork Cup
63.
Frame
1
Steel
Semi Gloss Paint
40mm OD X 25.4mm ID N/A
N/A
7.90 g/cm³
N/A
Fork Sheath
64.
Frame
1
Steel
Semi Gloss Paint
N/A
N/A
7.90 g/cm³
N/A
Stem
MFG Process
Nominal Wall Thickness
Tooling/ Setup Costs
Production Cost
$15,637
$5,245
Injection Moulded
5mm
$8,490
$1,389
N/A
STD Component
N/A
N/A
N/A
N/A
Bent Extrusion
2mm
Injection Moulded
3mm
$3,327
$3,362
STD Component
N/A
N/A
N/A
Die Cast
5mm
Section Assembly Time
Part Supplier
Amortized Part Cost/ 1,000
Amortized Part Cost/ 5,000
Amortized Part Cost/ 10,000
$4.85
$1.10
$0.63
$13.83 per 50
$13.83 per 50
$13.83 per 50
N/A
$2.80
$1.84
$1.22
N/A
$1.00
$1.00
$1.00
.125
$5.00
STD Part Cost:
Total Section Cost:
$1.94
$1.10
1,000 Parts
5,000 Parts
10,000 Parts
$13.90
$6.11
$3.82
$.62 $1.75
$0.52 $1.59
STD Component
N/A
N/A
N/A
N/A
Bent Tubing/Weld
3mm
$ 970
$ 945
2 min
$1.00 $2.48
Bent Tubing/Weld
2mm
$ 970
$ 498
2 min
$1.94
$1.74
$1.64
STD Component
N/A
N/A
N/A
N/A
$5.00
$2.00
$2.00
STD Part Cost: Total Section Cost:
1,000 Parts
5,000 Parts
10,000 Parts
$7.37
$4.19
$4.12
Bent Tubing/Weld
2mm
$ 2,000
$ 3,400
1 min
$3.50
$2.70
$2.96
Bent Tubing/Weld
2mm
$ 2,000
$ 4,870
5 mins
$5.00
$3.55
$2.54
Bent Tubing/Weld
2mm
$ 970
$ 1,340
2 min
$3.82
$3.20
$2.70
Die Cast
2mm
$23,257
$31,645
N/A
Sand Cast: $26.30
Die Cast: $4.80
Die Cast: $3.40
Injection Moulded
1.5mm
$16,580
$1,024
N/A
$5.30
$1.20
$.90
STD Component
N/A
N/A
N/A
N/A
$1.00
$1.00
$1.00
STD Extrusion
2mm
N/A
N/A
N/A
$ 3.50
$ 2.80
$ 2.19
STD Extrusion
2mm
N/A
N/A
N/A
$ 1.40
$ 1.23
$ 1.10
STD Extrusion
2mm
N/A
N/A
N/A
$ 2.40
$ 1.80
$ 1.63
STD Component
N/A
N/A
N/A
N/A
$3.00
$2.00
$2.00
STD Extrusion
N/A
N/A
N/A
N/A
$1.80
$1.70
$1.65
STD Extrusion
N/A
N/A
N/A
N/A
$1.21
$1.07
$.95
Total Section Cost:
1,000 Parts
5,000 Parts
10,000 Parts
$37.91
$17.21
$13.55
STD Component Supplier
McMaster Carr
Guangzong Zhengyu
Guangzong Zhengyu
Guangzong Zhengyu
Ningbo Maoying
56.
58. 57.
54.
28.
Bill Of Materials
52.
39. 51.
41. 38.
49.
40. 50.
42.
Assembly Name
Full Frame Assembly
Assembly Components List
Total Assembly Time
Total Labour Time
Labour Cost
Assembly Methods
Total Assembly Cost
.1 Hr
.1
$1.30
Jig loading Automated Welding Weld Cleaning
$4.30
.05 Hr
.05
$.86
Jig loading Automated Welding Weld Cleaning
$2.45
.1 Hr
.15
$1.94
Jig loading Automated Welding Weld Cleaning
$3.00
.1 Hr
.5
$8.40
Part Assembly Packaging
$11.40
Frame Tube Headtube Frame - Cross
Fork Assembly
Fork/Stay Tube Headtube inner
Frame Cast Assembly
Frame Cast Steatpost Outer Fork/Stay Tube Crank Sheath
Bike Partial Assembly & Packaging Handlebar Section Crank Section Cast Section
Total Welding Assembly Cost:
$21.15
1,000 Parts
5,000 Parts
10,000 Parts
Total Production Costs:
$68,530
$256,312
$480,100
Total Tooling Costs:
$85,047
$108,047
$108,047
Total Assembly Costs:
$20,150
$63,450
$101,520
Overall Product Costs:
$173,727
$427809
$619,667
Individual Part Cost:
$173.72
$85.56
$68.90
Selling Price:
$200.00
$140.00
$140.00
Profit Per Unit:
$26.28
$54.44
$71.10
Retail Price:
$250.00
$200.00
$200.00