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Elements and Performance Criteria

1. Identify frame requirements and prepare to design and build bicycle frame
   • Job requirements are determined from workplace instructions
   • Customer requirements are discussed and confirmed
   • Physical attributes of rider and his or her riding style are assessed using sizing cycle, observation and measurements
   • Bicycle frame design principles and design are researched and component specifications checked
   • Work plan and build instructions are prepared to use materials and time efficiently and minimise waste
2. Design bicycle frame
   • Frame is designed to meet customer measurements and requirements, using a bicycle computer-aided design (CAD) program or other means
   • Frame tubing requirements are specified in terms of diameter and wall thickness to meet durability and user requirements
   • Required parts and materials and their availability are determined
   • Frame costs are documented and customer approval is obtained
   • Order is placed with suppliers for frame materials, parts and components
3. Prepare for frame building
   • Frame building methods and sequence, and access to required tools and equipment, are planned
   • Parts are laid out and checked for damaged or missing components
   • Fabrication tooling and jig set-up are selected and checked for serviceability
   • Welding, brazing or bonding equipment and materials are set up
4. Build bicycle frame
   • Tools and equipment, including personal protective equipment (PPE), are selected and checked for serviceability
   • Frame building activities are carried out according to design drawing, work plan, and safety and environmental requirements
   • Hazards associated with the work are identified and risks are managed
   • Design drawing angles, measurements and frame alignment are checked throughout the building process and adjustments are made as required
5. Paint and finish frame
   • Frame is prepared for painting and finishing
   • Paint or finish is prepared and applied according to job and customer requirements and workplace instructions
   • Safety and environmental requirements, including the use of PPE and adequate ventilation during frame painting, are followed
   • Visible paint defects are removed or repainted according to workplace procedures and quality requirements
6. Complete work processes
   • Final inspection is made to ensure work meets workplace expectations and bicycle is presented ready for use
   • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected and stored
   • Tools and equipment are checked, reported if faulty, and stored according to workplace procedures
   • Workplace documentation is processed according to workplace procedures
7. Identify frame requirements and prepare to design and build bicycle frame
   • Job requirements are determined from workplace instructions
   • Customer requirements are discussed and confirmed
   • Physical attributes of rider and his or her riding style are assessed using sizing cycle, observation and measurements
   • Bicycle frame design principles and design are researched and component specifications checked
   • Work plan and build instructions are prepared to use materials and time efficiently and minimise waste
8. Design bicycle frame
   • Frame is designed to meet customer measurements and requirements, using a bicycle computer-aided design (CAD) program or other means
   • Frame tubing requirements are specified in terms of diameter and wall thickness to meet durability and user requirements
   • Required parts and materials and their availability are determined
   • Frame costs are documented and customer approval is obtained
   • Order is placed with suppliers for frame materials, parts and components
9. Prepare for frame building
   • Frame building methods and sequence, and access to required tools and equipment, are planned
   • Parts are laid out and checked for damaged or missing components
   • Fabrication tooling and jig set-up are selected and checked for serviceability
   • Welding, brazing or bonding equipment and materials are set up
10. Build bicycle frame
    • Tools and equipment, including personal protective equipment (PPE), are selected and checked for serviceability
    • Frame building activities are carried out according to design drawing, work plan, and safety and environmental requirements
    • Hazards associated with the work are identified and risks are managed
    • Design drawing angles, measurements and frame alignment are checked throughout the building process and adjustments are made as required
11. Paint and finish frame
    • Frame is prepared for painting and finishing
    • Paint or finish is prepared and applied according to job and customer requirements and workplace instructions
    • Safety and environmental requirements, including the use of PPE and adequate ventilation during frame painting, are followed
    • Visible paint defects are removed or repainted according to workplace procedures and quality requirements
12. Complete work processes
    • Final inspection is made to ensure work meets workplace expectations and bicycle is presented ready for use
    • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected and stored
    • Tools and equipment are checked, reported if faulty, and stored according to workplace procedures
    • Workplace documentation is processed according to workplace procedures

Range Statement

This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.

Customer requirementsmust include:	intended use of bicycle preferred design required construction methods and finish two of the following frame materials: steel titanium composite aluminium.
Frame building methods must include:	bicycle CAD drawings tube cutting, mitreing and preparation welding brazing bonding using frame jig controlling distortion and misalignment painting and surface finishing.
Safety and environmental requirements must include:	work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for: manually handling bicycle frames identifying workplace hazards using PPE environmental requirements, including procedures for disposing of waste materials.

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Performance Evidence

Before competency can be determined, individuals must demonstrate they can perform the following according to the standard defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

design and build two different bicycle frames to customer specifications, in which the frames must involve two of the following materials:

steel

titanium

composite

aluminium.

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Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to building bicycle frames, including procedures for:

manually handling bicycle frames

identifying workplace hazards

using personal protective equipment (PPE)

environmental requirements, including procedures for disposing of waste materials

sources of information on bicycle frame design and components

mechanical principles and requirements of bicycle frame systems and their relationship to braking, wheels, drivetrain and steering systems

types of bicycle frames and their system components

types and features of materials used in bicycle frames, including:

steel

titanium

composite

aluminium

types and use of tools and equipment used to design and build bicycle frames

procedures for sourcing bicycle parts and materials

techniques for designing and building bicycle frames, including:

application of frame design principles

bicycle computer-aided design (CAD) drawing

using measurements of customer physical attributes, including:

height

body shape and weight distribution

length of arms and legs

using measurements to design a bicycle frame to meet customer requirements, including:

head tube length and angle

bottom bracket drop

seat tube length and angle

top tube length

saddle setback

chain stay length

fork rake or offset

fork trail and bicycle stability

frame construction procedures and techniques, including:

component specifications

painted, anodised, natural state or polished frame surface

welding and bonding techniques

causes of frame failures and design alternatives to reduce failure.

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