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What are the Three Manufacturing Processes for Carbon Fiber Bicycles? |
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Carbon lugged frames are the grandfather of all carbon frames. Frames are constructed using a tube based design, meaning that each tube set is individually made and then bonded together at a joint. These joints are called lugs. Each lug is designed with a single purpose on a single fame size to make a very precise joining of the tube sets. Once tubes are joined, they are carefully hand wrapped at those joints to give a more seamless appearance to the frames. Not all lugged frames take this extra step, but we believe that even on a budget, you should get the smooth lines that make carbon bikes beautiful. It is the ease of construction that led us to type of build process for our Vitesse 100. Many of the leading builders in the industry use this method because of the ability to tune each tube set. Monocoque frames are now industry standard. They are relatively easy to make and are often misunderstood. They are not built as one piece as the name would lead you to believe. They are actually built in three pieces; the main triangle (or front half of the bike), the seat stays, and the chain stays. Each of these pieces is made of carefully hand laid carbon that is placed in a special clam shell mold with a high pressure air bladder inserted. The bladder is inflated to press the carbon against the mold. These pieces are placed in an oven and carefully heated and cooled. The three pieces are joined at the seat tube and carefully hand wrapped to create a one piece look. The great thing is that with this construction process, you can build some very impressive shapes. This is why we chose this manufacturing method for our Veloce 100 and Vitesse 200. While tube based bikes are the grandfather of carbon frames, they have made a comeback to the leading edge. With super high modulus carbon fiber, we set out to build one of the finest frames out there. Tube to tube frames consist of individually formed tubes, hand wrapped in a special carbon mapping process around a mandrel and inserted in a mold. Each tube is then pressed at incredibly high pressure to insure optimal compaction. These tubes are then mitered and joined together in a process called carbon welding. At these welds, the joints are then hand wrapped to give the frame a seamless look. This process currently builds the lightest, stiffest frames on the market. This is why we built our flagship frame in this manner. The Vitesse 300. Quite simply the best.
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