Carbon Fiber Bicycle Frame Manufacturing Process

Manufacturing processes vary greatly between companies and even by model but most composite bikes are made by arranging small strips right of carbon around a solid core inside a mold far.

Carbon fiber bicycle frame manufacturing process.

We were the first to build a usa made production ready full suspension carbon fiber mountain bike and we have won multiple best carbon bicycle and best carbon layup from north american handmade bike show. The process takes days of precise craftsmanship resulting in the award winning alchemy carbon fiber layup. Just as important as the carbon we select is the fiber orientation or layup schedule development which is how the carbon is wrapped or placed on the frame. Carbon fiber bikes made by hand.

The higher the quality the thinner the filament. Aluminum is the second most commonly used material for bicycle manufacturing. Like all ingredients carbon needs to be stored and maintained properly to maintain quality. Carbon fiber composite frames can be manufactured using the following two methods.

Processes of manufacturing monocoque manufacturing. When it comes to raw materials a very small percentage of bike builders use a rtm resin transfer mold based system where dry carbon fiber is injected with resin during the actual molding process. Commonly the lug material is now also a carbon fiber composite. Boutique manufacturers who specialise in custom geometries fits and lay ups find it extremely difficult.

Here s a condensed version of the step by step process. 2 weave the fibres together with resin to make pre preg sheets. Before manufacturing begins we select the specific fibers resins and weaves for each bike. Much like the.

It s lighter and stiffer than steel but it s also more brittle and easily damaged. Lugged frame construction and are held in place with glue. A carbon fiber composite frame or part. Every carbon fiber bicycle is made by hand.

A term commonly used to describe modern carbon fibre bicycle frames monocoque design. The individual plies of carbon are often cut from a sheet by a computer controlled machine but that s about the only automated process throughout production. Resin transfer rtm or fillament winding method used in lugged construction where pre formed carbon tubes are bonded to internal or external lugs see.