An overview of the technology of composite bicycle frames

While full monocoque forming is possible with smaller shapes and profiles, failure rates are high and the resulting quality may not be adequate. These additional test serve to add invaluable information that influence frame design and layup.

Commonly the lug material is now also a carbon fiber composite. This is due to the necessity to have compression material on the inside of the shapes that are being molded.

This is an example of an actual engineering layup diagram for the Velocite Geos with location, carbon fiber grade and orientation eg. There are several methods of making sure that the various layers are tightly packed together. At present, there are about workers in our carbon rim factory, and about workers in our carbon frame factory.

Because carbon fiber can be laid up precisely as desired, any shape and performance parameter can be obtained through combination of layup and shape of the mold.

The high importance of laying down patches of carbon fiber prepreg in different orientations is due to carbon fiber having maximum strength only along the lengths of the fibers. Therefore all monocoque frames in the market are actually made from several parts.

Composite literally means made of several materials - in this case carbon fibers, and resin. The act of spreading the tow results in a more 2-dimensional distribution of fibers, thus the fabric made from the spread tow can cover a larger surface area, than fabrics made from standard tow using the same number of fibers.

There is a recent trend to make ever larger elements for tube-to-tube construction so that the line between tube-to-tube and monocoque frames in terms of construction methodology is getting blurred. Tweet Carbon fiber composites currently offer the best weight, stiffness, durability and ease of use parameters out of all other materials available for bicycle component manufacture.

This is still how most of the carbon monocoque frames are made. This means that in order to achieve optimal stiffness at any part of the frame, once the basic shape requirements are met, all that is needed is to improve the carbon fiber layup and the manufacturing process used.

Since carbon fiber composite is a composite material that combines carbon fiber and resin, prepreg means that the carbon fiber has already been saturated with resin.


Our manufacturing partner also has a battery of custom tests that are not required by the CEN. This is generally accomplished by inserting air bladders into the laid up, raw frame, and inflating them once the frame is placed in the mold, prior to baking.

Unlike isotropic materials Read more about isotropy here: Carbon fiber layup Carbon fiber prepreg cloths of varying modulus and tow are cut into smaller patches according to the layup chart which varies for each frame model and size. There are no tubes as such, just hollow carbon shapes that handle all the loads.

You can observe this as faint mold lines on an unpainted frame. This deficiency affects all woven carbon fibers and cannot be easily overcome. Some of them have over 15 years experience in carbon frame bicycle industry, plus worked in OE factories for brands of Specialized, Cannondale, Pinarello etc The tubes themselves are commonly made via an RTM, or filament winding process where carbon tubes are woven around a solid mandrel usually steel, or alloy using carbon fiber yarn wound on a spool.

Lugged frame construction has no performance benefits over bonded tube, or monocoque frame construction. Closed mold using bag, foam core, sacrificial core, or polymer mandrel molding a Tube-to-tube, or bonded tube construction This method can be likened to welding the tubes together. Our main products are: We never start mass production until our new products pass all the tests successfully.

There are 8 layers in total using three different types of carbon fiber. Lugged construction using RTM or fillament-winding carbon tubes This was the original method of carbon frame manufacture and is a direct descendant of the lugged frame construction used for steel frames. Due to the smaller size of our company, production costs and the resultant increase in inventory costs are not a major concern for us.

This means that the carbon fiber materials and associated resins that the bike industry is using were originally developed for another sector such as aerospace.

As the name implies this type of fabric is made by "spreading" the tow, usually a 12k tow, to generate a tape that is much wider than the original 12k tow. Resin transfer RTMor fillament-winding method - used in lugged construction where pre-formed carbon tubes are bonded to internal, or external lugs see: When you look at a Velocite frame you can see the intricate structural top carbon fiber layer in full view.

Since then we started developing and manufacturing of carbon frames and carbon forks.A bicycle frame is the main component of a bicycle, onto International Journal of Science, Engineering and Technology Research (IJSETR), Volume 4, Issue 8, August Xiamen Lightcarbon Composite Technology Co.,Ltd has been specialized in manufacturing of carbon fiber bicycle frame and fork since founded in Our main products are carbon bicycle framesets,carbon bicycle wheelsets,carbon mountain bike frames,carbon bicycle wheels and so on.

An Overview of the Technology of Composite Bicycle Frames PAGES 6. WORDS 1, View Full Essay. More essays like this: composite bicycle farms, structural advantages of composites, making a bicycle frame.

Not sure what I'd do without @Kibin - Alfredo Alvarez, student @ Miami University. Carbon fiber use in the bicycle industry. Most commonly, the carbon fiber that is used comes in rolls of pre-impregnated fabric, or prepreg.

Since carbon fiber composite is a composite material that combines carbon fiber and resin, prepreg means that the carbon fiber has already been saturated with resin. Composite Material-overview. So the properties of the end product made from composites can be tailored to precise killarney10mile.comite bicycle frames have been a largely American phenomenon.

if the rigidity of each tube. there have been few high-end American bike companies that have been willing to learn this technology to develop. Composite frames are molded using layers of prepreg in a very specific sequence and orientation. In practical terms, this means that large components of the frame (like the front triangle) are formed as a single integral piece.

An overview of the technology of composite bicycle frames
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