Location : PRODUCTION

FACTORY PRODUCTION

Date： Publisher：

We have 20 years experiences in producing carbon bike parts, we mainly focus on the OEM production. We have rich experience in design, developing, producing carbon bike parts. We uses Toray Carbon T700/T800/T1000.

The main process of our production:

 

Material Preparation-  Cutting-Lamination- Cutting- Layup- Preforming- Molding- inspection- Clean up- CNC Machining- QC inspection- holes/Rivet- Trail Cutting- Sanding- Gluing- Baking- QC inspection- Masking- Painting- Baking- Fine Sanding- QC inspection- Putty Applying- Painting- Decaling- Polishing- Removable parts assembling- QC inspection- Record- Package

 

1. Design and Engineering

Computer Design： The process begins with the design phase where engineers create a detailed 3D model of the bike parts, let’s take frame for example. This includes considerations for geometry, aerodynamics, and rider ergonomics.

Material Selection: Engineers decide on the type and grade of carbon fiber required, mainly we use Toray T700/T800/T1000. Different fibers and weaves can be used for specific performance characteristics.

 

2. Preparation of Materials

Carbon Fiber Prepreg Cutting: Carbon fiber prepreg are cut into specific shapes and sizes based on the design. This allows for precise control over the layering of materials.

 

3. Layup Process

Layering: The cut carbon fiber sheets are layered up according to the frame design. This layer-by-layer process requires skilled technicians to ensure that the fibers are oriented in the optimal direction for strength and rigidity.

Preforming: A mold or tool is prepared, typically made from aluminum or composite materials, that gives the final frame its shape. The mold may be heated to facilitate the resin curing process.

 

4. Vacuum Bagging

Bagging the Layup: After the carbon fiber layers are placed into the mold, a vacuum bag is applied over the assembly. This setup removes air pockets and excess resin, ensuring a uniform and strong bond between the fibers.

 

5. Curing Process

Heat Treatment: The vacuum bagged mold assembly is placed in an oven or autoclave, where it is cured at elevated temperatures. This solidifies the resin and strengthens the frame.

 

6. Demolding

Removing the Frame: Once fully cured, the mold is opened, and the newly formed carbon fiber frame is carefully removed. This step requires precision to avoid damaging the frame during the demolding process.

 

7. Finishing Processes

Trimming and Machining: Excess material is trimmed, and necessary mounting points for components (like brakes, derailleurs, and internal cable routing) are machined or drilled.

Surface Finishing: The frame may undergo surface finishing processes, such as sanding, clear coating or painting to improve aesthetics and protect against environmental factors.

Final Assembly: Frames are fully assembled with removable parts.

 

8. Quality Control

Inspection: Each frame undergoes rigorous quality control checks to ensure that it meets strength, weight, and dimensional specifications.

Surface Finishing: Each frame surface needs to be carefully inspected by eyes.

 

9 . Packaging

Final Packaging: Products are wrapped by Polyethylene Foam before putting into the carton to avoid any scratch on the surface.

 

The production of carbon fiber bike frames is a complex and meticulous process that requires a blend of advanced engineering, skilled craftsmanship, and strict quality control. We continue to innovate in carbon fiber frame production, leading to lighter, stronger, more stylish and more efficient bicycles that cater to the demands of competitive cyclists and recreational riders alike.