Carbon Mold Pre-Forming & Layup

Carbon Mold Pre-Forming & Layup

Carbon Mold Pre-Forming & Layup Layup is the longest and most critical part of our manufacturing process.  Teams work together hand laying each carbon sheet in accordance to a strict recipe delivered to them in the form of a ply manual.  The team uses a variety of tools in order to preform parts with the the goal of consistency, efficiency, and getting them as close to the cured geometry as possible.

Frame Prep and Sanding

Frame Prep and Sanding

Frame Prep and Sanding After the overwraps are cured the bike is now 100% structurally sound, but still not ready to ride. In the final frame prep stage we do all the final machining and attach some of the small parts including cable management and water bottle rivnuts.  Also in this phase we sand the frame smooth to provide a good surface for a nice glossy finish.

Frame Prep and Assembly

Frame Prep and Assembly

Frame Prep Everyone thinks that the bike is 100% done once it comes out of paint. There’s actually more hours of labor involved in just prepping the frameset to place components on it. The frame threads are chased, and faced. All of the ports in the bike are polished. The cables are pre-run. Our kick-ass aluminum eagle is placed on the downtube.  Assembly After Frame Prep the frameset is then handed off  to our highly skilled Mechanics to build it out. Our mechanics come with a co...

Paint

Paint

Paint Personalization is no longer a luxury. It is a modern requirement for premium products. In the paint department is where the personalization and the individuality of each bike comes out.  We use the best quality products and painters in the industry to provide an unrivaled finish.

Carbon Fiber Over Wrapping

Carbon Fiber Over Wrapping

Over Wrapping Once epoxy used in the bonding process is cured, the excess epoxy is cleaned from the joint and a small wrap of carbon is placed around the joint to reinforce the bond.  This over wrapping step decreases the chances of paint cracks at the bond joint.  The wraps are cured with a sheet of silicon and shrink tape proving the compressive force on the joint.

Bonding

Bonding

Bonding The ALFA and ALLROAD are both triple monocoque designs. This means that the front triangle, chainstays and seatstays are all cured as separate parts, then bonded together to make the frame. After some very minor parts preparation after curing, the parts are ready to bond. They are placed into highly accurate jigs to ensure correct geometry and alignment. The bond areas are cleaned and a high strength 2 part epoxy is used to join the parts together. The bond areas are exposed to a s...

Carbon Curing in the Heat Press

Carbon Curing in the Heat Press

Carbon Curing in the Heat Press Now that we have removed most of the air from the laminate we can move on to curing the part. The envelope bag is removed and the tool is slid into a heat press. The press applies 20 tons of closing force on the tool and air lines are hooked up to the internal bladders. The press platens are heated to 130 degrees Celsius heating the tool. A thermocouple placed in the tool monitors the temperature of the part. The resin properties are rapidly changing as it h...

Carbon Mold Debulking

Carbon Mold Debulking

Carbon Mold Debulking Leaving layup, the result is a loaded closed tool that could go straight to curing.  The only issue with that is through the layup process we have unwittingly trapped a bunch of air in the layup.  Laying down sheets of carbon is not unlike laying down stickers, add to that a lot of complex curves and it is easy to visualize a bunch of small air pockets getting trapped.  If that air remains in place, it can cause voids, surface defects, and a host of both structural an...

Carbon Cutting & Kitting

Carbon Cutting & Kitting

Carbon Cutting & Kitting Carbon Cutting & Kitting begins the manufacturing process. After months of FEA, prototyping testing, and riding, the result is a recipe of over 300 unique carbon plies that will give the performance and strength desired in our bikes. These ply shapes are nested into cutting patterns and sent to our cutting team who cuts and organize the kits by part. The Mitsubishi fibers, pre-pregged in Irvine, California, provide the right balance of strength and stiffnes...