We developed a serial manufacturing technology for carbon bicycle frame components, designed to cut production cost and cycle time compared with conventional prepreg lay-up, while keeping the quality required in series production.
We have designed the technology for manufacturing carbon bicycle frames in such a way that, using it, the manufacturing cost is lower than any current technology in the world.
We developed a proprietary serial method for manufacturing hollow Forged Carbon (C-SMC) parts. The process preserves fibre continuity without shearing or shortening the fibres, which maintains the part’s strength, and keeps material waste to around 0.5% of the part weight with minimal finishing required.
We developed a manufacturing technology for carbon fibre profiles with variable shape and cross-section. By modifying both the process and the material system, we achieve a consistent laminate structure and a repeatable surface finish along the entire length of the profile.
We commissioned and optimised production lines for composite reinforcing bars (FRP rebar) and composite macro-fibres for dispersed concrete reinforcement, including modifications to the manufacturing technology.
We developed a technology for manufacturing large carbon fibre parts out of autoclave (OOA). By modifying OOA materials and the vacuum-bag process, we achieve layer consolidation comparable to autoclave curing, with a high-quality laminate structure and surface finish – without the size limits and cost of an autoclave.
We have developed parts, moulds and manufacturing processes for a range of bicycle components. We presented selected solutions, including hollow Forged Carbon (C-SMC) parts, at JEC World (France), Hannover Messe (Germany), Kompozyt Expo (Poland) in 2022.
From hollow forged carbon parts and a serial manufacturing technology for bicycle frame components to the landing gear of an ultralight helicopter – below are the projects we can describe publicly. Most of our work for industrial customers is covered by non-disclosure agreements. We are happy to discuss details in person, including under an NDA.