Currently working to produce my own custom carbon fiber bike frame. Currently in the later stages of the design phase, and about to purchase supplies to make the frame (starting with fiberglass and then moving to carbon fiber after). Bike frame was modeled entirely in NX Cad, and simulated using NX FEA software as well (as isotropic aluminum for now - working on some NX Laminate simulations as well).
The tentative plan is to model the frame, then use either a foam hot wire cutter to cut of the foam into the frame design using some guides printed from the CAD model or a Shopbot to cut the foam out, then wrap the composite over that and vacuum bag it. Please check out my portfolio at www.sambelden.com for updates. I'll try to post some simulation photos shortly!