Hayes Brake Adapter
I designed and machined this Hayes mount brake adapter for a cycling buddy so that he could run IS disc brakes an old Maurer frame. It took several iterations, 3D printed prototypes, and some adjustments based on FEA, and the final result was a lightweight and stiff adapter.
Evaluated specifications from design drawings and measurements of the frame
Modeled all parts in Solidworks using 3D surfaces
Iterated design with a series of 3D printed prototypes to check interference and FEA analysis to evaluate max Von Mises stress and deflection
Worked with local machinist (Z9 Machining) to set up CAM and run multiple operations on a Hardinge Bridgeport VMC GX-1000 OSP machine