Carbon Fiber Bicycle Frame Manufacturing Process

It s lighter and stiffer than steel but it s also more brittle and easily damaged.

Carbon fiber bicycle frame manufacturing process.

Here s a condensed version of the step by step process. Resin transfer rtm or fillament winding method used in lugged construction where pre formed carbon tubes are bonded to internal or external lugs see. A carbon fiber composite frame or part. Not all carbon is created equal.

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. 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. Of the lead materials used for bike frames ranging from aluminum to titanium and even carbon fiber chromoly offers the best cost benefit ratio. A term commonly used to describe modern carbon fibre bicycle frames monocoque design.

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. Boutique manufacturers who specialise in custom geometries fits and lay ups find it extremely difficult. 1 it takes 5 000 to 12 000 carbon filaments each between five and seven micrometers thick to make a single carbon fibre. 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.

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. Much like the. Carbon fiber composite frames can be manufactured using the following two methods. 2 weave the fibres together with resin to make pre preg sheets.

Commonly the lug material is now also a carbon fiber composite. The process takes days of precise craftsmanship resulting in the award winning alchemy carbon fiber layup. Lugged frame construction and are held in place with glue. Before manufacturing begins we select the specific fibers resins and weaves for each bike.

Aluminum is the second most commonly used material for bicycle manufacturing. Every carbon fiber bicycle is made by hand. Processes of manufacturing monocoque manufacturing.