Carbon production

This much can be said: there are various ways to produce carbon parts. The way we do it is highly innovative. It is the result of years of experience, development work and a passionate commitment to premium quality. For example, our frames are baked in the autoclave in one piece and not - as is usually the case - assembled from individually manufactured segments. This is called one-piece monocoque. It makes the frame as light and stable as possible. At just 794 grams in size M, our MTB frame THE FRAME is one of the lightest in the world. The carbon frames for Stoll Bikes and Last Bikes, which are produced in our factory, are also in a league of their own, as many test wins in magazine tests prove.  

So how is THE SUPERFAST made? We can't reveal everything. But we want to keep the production process as transparent.  

Step 1: Construction of the molds
As soon as the development of the frame is complete, the mold is constructed. This consists of two parts. Each frame size requires its own mold. There are also molds for the fork and cockpit. The molds are milled from aluminum by a specialist company.  

Step 2: Layup development
A carbon component is a highly complex puzzle made up of many different pieces of carbon. Not all carbon is the same. There are fibers in different thicknesses and with different tensile strengths. Carbon has its perfect properties along the fiber. Depending on how the layer is positioned in the mold, it can withstand pressure, tension or torsion. The layers are cut from large fabric mats. A bike Ahead handlebar consists of 28 layers, a wheel and a frame of up to 90 layers.

Which fibers are optimal for THE SUPERFAST? How should they be arranged? What shape does each individual layer have? No computer program provides the answers. Everything is developed step by step. An intensive process. But we don't start from zero. After all, we already have a lot of experience with the construction of carbon parts.  

Step 3: Prototype production
The first prototype is something like a ball that you roll into the playing field. It is the start of the final development phase. Every frame that is created from now on undergoes rigorous testing. First on the trail, later on the test stand. This provides important insights into the strengths, but also possible weak points. The layup is further optimized during this phase. Until THE SUPERFAST is absolutely perfect.  

Step 4: Preparing for series production
The production of a frame cannot start from one day to the next. It requires lengthy preparation. Very important: employee training. The laminating crew has to learn where each individual carbon layer has to sit. This process takes two months. There are also many other things that need to be organized for the start of production. Small parts like the saddle clamp. The shipping carton. And much more.  

Step 5: Start of series production
It will be a big moment that we will celebrate: The frame number 001, which has hung framed in our manufactory as motivation for everyone involved since the start of THE SUPERFAST project, will be inserted into the mold. One day later, it will decorate the freshly baked frame.

The lucky owner will be there. Because THE SUPERFAST number 001 will be raffled off among all those who gave their input into its development. In other words, among those who have commented on and shared our social media posts. And among all those who have sent us emails.

Want to be part of it? You can find all information about the raffle on this THE SUPERFAST home page.