Anyway, here are three things that we do with our carbon fiber bikes that are unique, and that we can share with you without having to have your memory erased afterward:
By laying up and curing the front triangle all at the same time, and not assembling together pieces, we're able to decrease the amount of material used by eliminating overlapping joints that have to be bonded or wrapped with carbon. Less material means fewer grams. This method is extremely expensive to do, since each size has to have a lot of dedicated tooling, nothing is shared between each size.
The one-piece lay-up of the front triangle allows continuous fibers to be used that wrap between tubes, allowing the structure to distribute loads better, and absorb impact energy. We also are able to truly integrate the shock mounts, pivot mounts, dropouts and disc brake tabs into the structure, using all uni-directional carbon plies. The shock mount isn't merely riveted or bonded on after curing, but an integrated part of the fiber lay-up. This makes our carbon frames incredibly strong and able to absorb impact better than any other frames we've tested.
Our lay-up process allow us to control the outside shape, inside shape, and to compact the fiber layers during the lay-up. This eliminates gaps between layers, and keeps resin from migrating to the inside of the tubes, or allowing delamination during the molding process. You can't see this without getting inside the frame, but we're more proud of how the inside of these frames look than the outside. No gaps, no filler or mystery material. No resin pools, or glued together sections. It's a frame you wouldn't be embarrassed to bring home to mom. No skeletons in the closet, and no rider weight limits either.
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