When it comes to bicycle frames, one of the most popular materials on the market today is carbon fiber. Carbon fiber frames are usually some of the lightest and strongest on the market, and can be made to extremely precise dimensions for the perfect ride. But how exactly are these frames manufactured? We take a closer look behind the scenes at carbon fiber frame manufacturing to explain.
At the heart of all modern carbon fiber frames is a piece of carbon fiber cloth. This cloth is made up of thousands of tiny strands of carbon fiber woven together into a fabric. This fabric is usually woven in a patterned weave designed to give the cloth uniform strength in all directions. Once the fabric is ready, it is time to make frames.
Frames are generally manufactured in a process known as filament winding. Filament winding is a process where cloth is laid down in a mold and then layers of precision fibers are wound around the fabric to form a complete frame. The frame is then ready for molding. This is done in an autoclave, where the frame is sealed into a chamber and a vacuum is applied using pressurized air. The pressure from the air and the vacuum combine to form a strong bond between the carbon fiber strands, which form the frame.
Once the frame is ready, it is cut into shape. This is usually done with a computer-controlled router or water jet. The frame is then painted or clear coated with a protective finish. This will add extra strength and protection from the elements to the frame.
The last step is to assemble all the components of the frame. This usually includes the brakes, chain, gears, handlebars, and wheels. Once the frame is fully assembled, it is ready to be sold.
carbon fiber frames are some of the lightest and strongest frames on the market. By taking a look behind the scenes, it is possible to gain a better understanding of the carbon fiber frame manufacturing process. Knowing the details about how frames are created will help you make the right choice when buying your next bike.