Abstract. This paper presents the design of sustainable paper bicycle which describes the stage by stage in the production of paper bicycle. The objective of this project is to design a sustainable paper bicycles to be used for children under five years old. The design analysis emphasizes in screening method to ensure the design fulfil the safety purposes. The evaluation concept is presented in designing a sustainable paper bicycle to determine highest rating. Project methodology is proposed for developing a sustainable paper bicycle. Design analysis of pedal, front and rear wheel, seat, and handle were presented using AutoCAD software. The design optimization was performed to fulfil the safety factors by modifying the material size and dimension. Based on the design analysis results, it is found that the optimization results met the factor safety. As a result, a sustainable paper bicycle was proposed for children under five years old.