A design methodology for an innovative racing mini motorcycle frame

Sports equipment design is a young and evolving engineering discipline focused on the best simultaneous optimization of user and product as a system. In motorsports, in particular, the final performance during a race depends on many parameters related to the vehicle, circuit, weather, and tyres and the personal feelings of every single driver. Top teams in high-tech categories can invest huge amounts of money in developing simulators, but such economic commitment is not sustainable for all those teams that operate in minor but very popular categories, such as karts or mini-motorcycles. In these fields, the most common design approach is trial and error on physical prototypes. Such an approach leads to high costs, long optimization times, poor innovation, and inefficient management of the design knowledge. The present paper proposes a driver centred methodology for the design of an innovative mini racing motorcycle frame. It consists of two main phases: the drivers’ feelings translation into engineering requirements and constraints, and the exploration of the design solution space. Expected effects of the application of the proposed methodology are an overall increase in the degree of innovation, time compression, and cost reduction during the development process, with a significant impact on the competitiveness of small racing teams in minor categories.