The fuel consumption of vehicles can be affected by the weight of the vehicle. Trending on replacing the metal part or product with lighter composite material has emerged. By using polymer composite instead of metal material in producing an automotive component, the total weight of the vehicle will be reduced. This research aims to develop the conceptual designs of new lighter weight motorcycle handle brake lever by integrating Theory of Inventive Problem Solving (TRIZ) and FEA simulation. This research generates the best concept design based on user needs and product design specifications. TRIZ contradiction matrix and 40 inventive principles solution were applied in the early solution generation stage. The principle solution parameters for the specific design features were later refined using Morphological Chart to systematically develop numbers of concept design. After numbers of significant FEA simulation, decision-making processes are performed in selecting the most appropriate concept design. A design was selected as the best conceptual design as it has scored the highest in the concept rating. This research proves the significant contribution of integrating TRIZ and FEA simulation that will benefit the industry in conceptual design phase of producing a new product.
