Kids Balance Bike – Design for Manufacture & Structural Engineering

As part of a collaborative product development project, I co-designed a children’s balance bike with a primary focus on manufacturability, structural integrity, and compliance with real-world production constraints.

My role centred on Design for Manufacture (DFM) and engineering validation. From the outset, I ensured all injection-moulded components adhered to manufacturing best practices, carefully controlling wall thickness to prevent sink marks and warping while maintaining consistent plastic flow throughout the mould. Draft angles, parting lines, and gate placement were considered during CAD development to ensure efficient tool design and reliable part ejection.

To optimise strength without unnecessary material usage, I incorporated strategically placed ribs to reinforce high-stress areas while maintaining uniform wall sections. Finite Element Analysis (FEA) was conducted to evaluate stress distribution across the frame and load-bearing components, allowing iterative refinement before finalisation. This ensured the design could withstand the dynamic loads expected during real-world use.

For the wheel assembly, I accounted for tolerance stacking to ensure accurate fit between rotating components and the axle system. Particular attention was given to achieving smooth rotational performance while maintaining manufacturable clearances. The tyre was designed to be overmoulded onto the wheel core, using a combination of mechanical interlocking features and chemical bonding compatibility to ensure secure adhesion and long-term durability.

This project strengthened my ability to design beyond aesthetics — balancing engineering performance, material efficiency, manufacturing feasibility, and child safety considerations. It reflects my approach to product design: creative thinking grounded in technical realism and production-ready execution.