Carbon Fiber Bicycle Programme
Carbon fiber bike is one of the success case areas developed by the CarbonWizer team, covering aerodynamic road bicycle frames and components.
Who the Work Was For
Bicycle and scooter brands developing composite frames and components. Carbon fiber bike and scooter products are one of the four main CarbonWizer product groups.
Project Challenge
A bicycle frame has to be stiff where power is applied and compliant where the rider sits, at a weight that metal cannot reach. That is a fibre architecture problem, not a material selection problem.
Customer Pain Points
- Weight targets that aluminium and steel frames cannot meet
- Stiffness and comfort pulling in opposite directions
- Tooling investment required before a new model is proven
Our Solution
Frame tubes and components are built from unidirectional prepreg with layers of fibres oriented at different angles to provide properties designed for the specific application, in standard, high modulus and ultra high modulus grades.
Manufacturing Process
Roll wrapping for tubular sections, with compression moulding and autoclave cure for junctions and formed components. Mould design and making are carried out in house.
Supply Chain Coordination
Frame components are produced alongside any metal inserts or fittings the design needs, so the assembly arrives complete.
Quality Control
Sections are produced to the stated nominal diameters and wall thickness, and surface finish is inspected on visible frame faces.
Final Result
Carbon fiber bike and scooter products remain one of the four main product groups produced by the CarbonWizer team.
Customer Benefit
Brands can tune ride characteristics through fibre orientation rather than through tube diameter alone, and validate a frame before committing tooling.
Parts Behind This Project
Carbon Fiber Tube
High strength carbon fiber tubing fabricated with unidirectional prepreg and wrapped in 3K plain or twill fabric, in fifteen stock part numbers from 5.0 mm to 242.0 mm nominal inside diameter.
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Carbon Fiber Structural Arm
A full carbon fiber arm made as a verification sample, carrying the strength and stiffness of a production composite part so the structure can be tested before a mould is cut.
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Carbon Fiber Sheet
Stock carbon fiber plates fabricated from multiple layers of high strength prepreg under high pressure moulding, in ten thicknesses from 0.5 mm to 5.0 mm at 500 x 400 mm.
View detailsQuestions About This Case
Can you share the customer name?
No. Customer names are withheld, so projects are described by type and sector rather than by buyer.
Can you reproduce this kind of work for us?
Yes. The same route is available - requirement analysis, material and process selection, mould design and making, prototyping and production.
How long would a project like this take?
Sample orders are normally shipped within one week, and normal production orders take 15 to 25 days. Tooling lead time is quoted separately per part.
Have a Similar Project
Email the drawing, the sector and the quantity. Projects like this one start with a structural sample before any tooling is committed.