Frame Construction

We believe in using construction methods that produce high-performance bikes of the highest quality, no matter the cost.

Headtube Mold

Bladder Molding

Bladder molding is the most sophisticated process currently used in lightweight hollow composite construction. Compacting the layers of material in the carbon fiber laminate is one of the keys to making a light, strong part.

Each frame is made up of multiple bladder molded parts. By making the front triangle in three parts, we have access to the inside of the part. This allows us to use perfectly form-fitting bladders, intensifiers, and internal molds to make sure every surface is perfectly flat, smooth, and compacted.

Compression Molding

The dropouts have a job that is different from the rest of the frame. The dropouts, which also hold the rear brake, are drilled and counterbored for the brake, and drilled for the axles and the derailleur hanger. They are squeezed between the axle and the hub and machined so everything fits perfectly. All of which would compromise a long-fiber part. As a result, the dropouts require a different construction method.

To make the dropouts, we use a process called compression molding. Rather than using long fibers laid up in specific orientations, compression molding uses chopped fibers (confetti) that are randomly packed into a mold and cured under pressure.

Bonding Carbon Frame

Frame Assembly

Once all of the frame’s parts have been made, they are prepared for assembly. We remove all flash, trim extraneous material, check all specifications, and dry fit the parts. Next we prepare the parts for bonding, one of the most important steps of frame assembly.

The frame parts are bonded in a very precisely aligned frame fixture. After the frame has cured, we transfer it to an inspection plate to verify that its alignment is correct. Then we apply a non-structural carbon over-wrap at each of the joints to produce a smooth and seamless final frame.

Testing and Quality Control