Carbon

The carbon tubes are built by using special moulds and during the polymerization the resin is injected at high pressure. This operation allows a better distribution of the resin among the fibers, in order to have a more compact structure.

Honeycomb technology: this denomination indicates a new process of manufacturing that is new in the bicycle industry but has been used a long time in racing cars and in the aerospace industry, where there is the need of high resistance light materials, like the carbon fiber and kevlar. By these two products is realized a sandwich structure: between two layers of carbon fiber, combined with a layer of nomex, which is a material made of aramide which takes the shape of an honeycomb. This kind of building and the use of nomex in the tubes, allows to have a frame very rigid. the use of fiber both resistant with elasticty in their disposition, gives high torsion, rigidity and high resistance to the given demands.

Ways of building a carbon frame

The carbon frames are made by the “tube to tube” or “carbon wrapped” process or by the monocoque process.

The “tube to tube” or “carbon wrapped” process and the custom made frame.

The manufacturing system “tube to tube” or “carbon wrapped,” is a process in which the carbon tubes are bonded by carbon wraps crossed at various angles to obtain maximum strength at the points subjected to the greatest stress. This process creates a homogeneous structure with similar characteristics to a monocoque frame but with the added ability to make custom frame geometries

Considering the body measurements of the customer , the technical characteristics of the bike are improved offering the perfect sizes and eliminating the physical problems caused by a wrong position while riding.

The tubes are cut and milled then assembled using structural adhesives then the junction points are wrapped with prepregnated carbon layers. The frame is put in autoclave and then in an oven in order to obtain a rigid and lightweight structure.

The monocoque process The monocoque frames are built by moulds in which are put prepregnated carbon layers; the mould is then pressurized and put in an oven in order to polymerize and solidificate the resin.

ALLOY

The alloy frames are built with the class 7005 and Scandium 7000 alloy tubes, which are light with good mechanical resistence and high elasticity.

The alu frames are tig (tungsten inert gas) welded and then submitted to an heat treatment in a special oven that helps to recover the mechanical characteristics lost during the welding process

HONEYCOMB CARBON TECHNOLOGY