Why use carbon?

To manufacture our carbon frames, we use high-quality, pre-prepared, unidirectional fibers (all of the fibers are positioned in the same direction). By playing with the number of layers and the direction of the fibers, we can obtain the stiffness we want in the places we want. Our carbon fibers have the best density/performance ratio that exists, which allows us to obtain the lightest frames possible.

We use two different types of fibers, High Modulus (HM) and High Resistance (HR). HM fibers are stiffer and lighter than HR fibers, therefore allowing us to improve the performance of the frame. HM fibers are used only on our high-end carbon frames that you’ll find in our new Web Series.

Performance software

Once we have defined the various technical solutions in theory, we design the frame in 3D with CAD (Computer Assisted Design) software, which allows us to visualize the new frame. The frame is then recreated using a finished element calculating software that simulates the behavior of the frame under different conditions. Using the information from the simulations, we can identify the parts of the frame that are put under the most stress and therefore determine the optimal direction of the fibers and the number of layers necessary. The end result is a high-performance frame with the best weight/performance ratio possible.

Manufacturing process

To start, strips are cut from the pre-prepared tissue and draped over a mandrel in the pre-defined direction and thickness. Next, a bladder is inserted in the tube, which is then positioned in the mold. The mold is placed in a press and the material is cured by increasing the pressure in the bladder. The mold is subsequently heated in order to polymerize (or harden) the resin. The tube is then taken out of the mold, with the desired characteristics previously determined using the computer software.

The different tubes are molded seperately and then assembled with a special glue, which is the heart of our T3 (“Tube To Tube”) carbon technology. This assembly process is done without lugs, for an even lighter frame.

Striving for performance

Numerous tests are performed by computer in order to design the most performing and lightweight frame. Once the frame is approved on the screen, prototypes are manufactured in order to test the frame in real conditions, especially with the riders from the Française des Jeux. Their feedback, as well as the results from our in-factory test machines, allow us to determine which parts need improvement. In general, several computer/prototype phases are necessary before the frame is approved for production.

We have developed two distinct carbon frames this year. The X-Lite is a very stiff frame that offers maximum efficiency and optimized performance. The S-Lite has tube forms that offer more comfort, with 25% more vertical flexibility in the rear triangle than the X-Lite, for better absorbtion of vibrations from any deformations in the road.

T3 Technology for Mountain Bikes

Unlike the tubes used for our road frames, our carbon MTB tubes are closed at the ends, which gives us a greater gluing surface for additional fine-tuning. The overlap is therefore created for a different purpose: because we achieve a better connection from the closed ends, the overlap can be optimized for the overall aesthetic aspect instead of serving as a connection.