Sheet Metal Design

Custom
Bike Rack

A purpose-built accessory that carries a backpack on the side of a bicycle — designed from scratch, prototyped in plywood, and fabricated in sheet metal. No off-the-shelf solution existed for this application.

Material
Sheet Metal
Fabrication
SendCutSend
Processes
Laser Cut · CNC Bend
Status
Completed
Technical Deep Dive
Custom bike rack CAD render
The Problem

The existing rack and basket can carry my backpack, but carrying a backpack there would block it for other use.

The Solution

The solution: bolt a custom bracket to the side, using the bike's own hardware as the mounting interface.

No modifications to the bike. No modifications to the backpack. I wanted it to be as integrated as possible, while also plainly being an accessory.

Shelf locking mechanism detail
01
Reverse
Engineering
02
CAD
Rev 1
03
Plywood
Prototype
04
CAD
Rev 2
05
Sheet Metal
Order
06
Assembly
& Finish
For Engineering Reviewers

Technical Deep Dive

Full documentation: design decisions, reverse engineering methodology, prototype iterations, DFM considerations, manufacturing specs, and process notes.

View Full Documentation