FACTOR 001 is the result of a creative project by BERU f1systems to explore the transfer of design approaches, technology and materials from Formula One to a groundbreaking training bicycle. The design brief did not require the bicycle to comply with existing technical regulations, which resulted in great freedom during the design process. This paper details how OptiStruct Optimisation tools were used to help generate efficient lightweight solutions for the design of complex carbon fibre components. Free-size optimisation was used to generate laminate boundaries, ply thicknesses and fibre directions, which met stress and displacement requirements. Physical testing carried out on manufactured parts highlighted the accuracy of the FE models and demonstrated the advantages of incorporating OptiStruct Optimisation tools in the design process.