Frame Production Technology
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LightCarbon Ultra Aero Triathlon Carbon Frame Disc Brake 700C Carbon Fiber TT Bike Frameset - Professional Triathlon carbon frameset - Super aero and ergonomic design - Designed with specific aero water bottle and tool box - Press fit BB386 bottom bracket - Max 700x28C tire clearance - Disc brake (flat mount) - Di2 compatible - Full internal cable routing more
LightCarbon Mid-range Widened Gravel Carbon Wheels Ratchet System Hub 700C Wheel For Gravel Bike • Gravel carbon wheels with widened carbon rims • C52DB mid-range hubs, with 36T ratchet system, ceramic bearings • Widened 26mm inner width, fit 700Cx35C-50C tires • With depth 40/45/50mm optional • Shimano 11/12s HG or SRAM 12s XDR optional • Pillar 1423 Spokes, aero & strong more
LightCarbon 3D Printed Carbon Saddle High-end Ultra Light Bike Seat Carbon - 3D printed saddle top, honeycomb structure - T800 carbon fiber saddle rail+base - Ultra light weight, only about 149g! - Stiffer 3D print material, more favorable for racing. - Length x Width = 245 x142mm - Rider weight limit 100kgs - Suit 7x9mm seat post clamp - Easy to clean more
LightCarbon Super Light Full Carbon Bottle Cage Bicycle Bottle Holder - Full carbon fiber material - UD Black matte finish - Customized logo is acceptable - Super Light weight, only around 19.5g more
LightCarbon Gravel Rims Widened 26mm Inner Width 700C Carbon Rims For Gravel Bike • Widened 26mm inner width, for 37C-50C tires • 40/45/50 height optional • Reinforced lay-up structure • Designed for CX/Gravel bikes • Tubeless ready • High quality, 2-year warranty more
29mm Width 700C Disc Brake Carbon Road Rims - Widened 23mm Inner Width (29mm outer width) - Optional rim depth: 38/45/50/55/60mm - Clincher (Tubeless Ready) - Wide U shape design, more aero and stiff - High quality carbon rims, with 2-year warranty more
Lightcarbon 3-Spoke Carbon Wheel 120mm Depth 28mm Wide Aero 700C Tri Spoke Carbon Wheel • 120mm depth, 28mm width, better aerodynamics • ProX hub with 36T Ratchet system • Tri-spoke carbon wheel for 700C Road/TT/Track bikes • Clincher (Tubeless), fit 700x28C-45C tire • Black/12K, Matte/Glossy finish optional • Disc-brake & Rim-brake version optional more
Carbon Frame Production
LightCarbon Frame Production
LightCarbon manufactures and develops high end carbon fiber bicycle frames and accessories since 2016, has rich experience in integrated molding, design and manufacturer of different bicycle frames(Road/MTB/Electric bike frames).
The production processes are as follows:
Carbon fiber cutting->preform->forming->processing->gluing->primer->Test rigidity->coating->assembling->packing-> shipping
All the above sections have QC complete inspection and qualified to the next section, QC standards see Quality Control.
Cut Carbon Fiber Pre-preg
As shown in figure C01-C02-C03-C04-C05 below, all carbon carbon fiber cloth should be kept at a constant temperature, below 22-24 degrees, and finished within 10 days of use. Unused materials should be stored in a freezer, the temperature of the freezer is between 0-5. In this section, the carbon fiber is cut according to the Lay-up design and the material pieces are separated and sorted by a special person. The Lay-up design of a normal frame is 130-150pcs, we set up the commissioner to separate all the pieces into a set of after-transfer professionals for the production of products, the equipment used in this section for automatic cutting machine, chopping machine etc...
As the following figure L01-L02-L03-L04-L05, preform is a very important process for carbon fiber products, directly related to the strength, size, appearance etc... it's easy to make a good product out of carbon fiber, a special material, but it's hard to make 100 products that are exactly like the first one, therefore must have the strict operation personnel and the QC to the SOP cognition and the rigorous. All operators strictly follow the development settings of LAY-UP production, integrated Mandrel technology plus vacuum operation, from the first step to 150 steps of lay-up, the position of the sheet is fixed, the position of the reinforcement is strengthened, and the epoxy is filled, the air duct into the mold molding reserved and positioned for the next stage of molding preparation in advance. All products related to personal safety, we are use the premium import Japenese Toray carbon fiber like Toray T700/T800/T1000.
Molding this section is the most important for the products, GO and Ng is basically decided by this section, this section of the production equipment is high temperature and high pressure, it is in this special environment to promote a good product. As shown in figure A01 and A02 for this section of the production and placement of mold die, figure A03 for CNC machine automatic mold opening, we self-procurement CNC machine, shorten and ensure the opening time and quality, A04 for the opening of the mold after the physical. We from R & D design-self-mold-production-shipping, such as a set of perfect process.
Figure A05 is a pre-formed 1:1 product placed in the mold after the high-temperature molding into the table as shown in figure A06, and ensure that the molding Taichung temperature is 120 degrees, high pressure is 150 psi, mould should be formed in high temperature and high pressure for 1.5 h, then the mould should be cooled and opened to produce, as shown in figure A07 A08.
As shown in the following figure K01-k04, this section for the removal of product scraps and cutting excess pipe processes, related to the drilling accessories. When cutting excess pipe material, the operator shall strictly follow the cutting SOP stipulated in the development section, sandblast coarsening was carried out on the joint parts of the pipe fittings afterwards in order to provide bonding strength for the bonding of the lower section.
Figure K05 shows that the E-BIKE battery and motor area are processed with high precision. The equipment is CNC. Because the E-BIKE requires a higher assembly size for the motor battery, the processing cost is also high, fig. K06 is the real object after CNC machining. It can be seen that the machining area is uniform without burr and the dimensional accuracy is also high.
This section is the product for gluing, using high-temperature Epoxy, high-temperature baking fixed. For example, Q01 is the place before gluing, and Q02 is the frame waiting for gluing. Before gluing, each gluing part should be cleaned with alcohol to ensure the gluing strength. Figure Q03 Q04 is for gluing the product. It is carried out according to the SOP. All aluminum parts need to be cleaned by sandblasting before gluing. Fig. Q05 is to measure the upper placental position of the special fixture for the product to ensure the correct placental position after bake fixation. Other fixation methods are performed according to the SOP, fig. Q06 put the tools into the high temperature oven for baking. The baking time is 1.5 h. the oven door can not be opened during this time, in case the temperature reduces the strength of the glue and the frame.
Figure Q07 is glued frame platform inspection, in accordance with the development of the SOP set standards, if you want to understand the inspection items, please see Quality Control.
The frame of the good product is carefully polished and mended by QC to ensure smooth appearance of the frame,the rigid inspection is performed by the QC part after fine completion. The purpose of the inspection is to check whether there are cracks on the surface of the product due to filling the soil too thick. The test is non-destructive and is performed according to Sop set by the development.
For rigidity testing, see Product test.
email : info@lightcarbon.com
add : 4/F, NO.3 Bldg, Longtou Industrial Zone, NO.9 Xingmei Road, Xiamen, 361022, China
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