Carbon Fibre Bicycle Frame Manufacturing Process

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. Resin transfer rtm or fillament winding method used in lugged construction where pre formed carbon tubes are bonded to internal or external lugs see. Most frame manufacturers build frames with sheets of carbon fibre that is pre impregnated with uncured resin better known as pre preg applied to a non stick paper backing and shipped on large.

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Lugged frame construction and are held in place with glue.

Carbon fibre bicycle frame manufacturing process.

Like all ingredients carbon needs to be stored and maintained properly to maintain quality. 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. Before manufacturing begins we select the specific fibers resins and weaves for each bike. 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.

1 it takes 5 000 to 12 000 carbon filaments each between five and seven micrometers thick to make a single carbon fibre. 2 weave the fibres together with resin to make pre preg sheets. Commonly the lug material is now also a carbon fiber composite. Carbon fiber composite frames can be manufactured using the following two methods.

Here s a condensed version of the step by step process. The higher the quality the thinner the filament. Not all carbon is created equal.

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