Mold Development
Carbon and Bread. More in Common Than You Think. Both start in a mold. Both are baked. While your local baker gets by with a simple metal tray, crafting a carbon bike frame takes something a little more advanced - like a high-precision mold. Into these, we carefully place each layer of prepreg carbon. An inflatable bladder is inserted, which presses the layers into place during the baking process - then removed once curing is complete.
The mold itself is part of the design process from day one. Take the cockpit: with multiple stem lengths and bar widths, the tool is made up of nearly 60 individual components. It’s a 3D puzzle, each piece precision-machined down to the hundredth of a millimeter. The fork and frame molds? Equally complex. Designing a perfect bike is one thing. Building it requires perfect tooling. That’s why we’ve partnered for years with a trusted mold maker just a short drive from our headquarters. Proximity means fast feedback, tight timelines, and hands-on collaboration. Once we finish the CAD files, they’re translated into CNC code - a task that takes days, not hours. Every mold is machined from solid blocks of aluminum, chosen for its thermal conductivity and dimensional stability. What happens next is under wraps. The mold secrets are like the formula for award-winning bread - passed down, closely guarded, and key to the final masterpiece.
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