Key design elements included the lightweight frame and a three-point folding pattern. Type and lay-up of the composite reinforcement were discussed at length between manufacturing and the structural analysis teams. They selected carbon fibre-reinforced epoxy prepreg from Microtex Composites (supplied in the UK by Total Composite Solutions), which is hand laid up and vacuum-bag/autoclave-cured on CFRP tools. Microtex X1 Matrix epoxy system was also chosen for its structural performance and visual clarity for the frame. Loose tool inserts are used to create all mating surfaces where seat/head and bottom bracket are inserted and bonded during assembly. Fully cured resin is rated for a continuous-use temperature of 80°C. The 2×2 twill-weave, bi-directional surface piles use 245 g fabric while unidirectional backing plies are 660 g and are also used as added reinforcements in high-stress areas. It takes about 18.5 hours to hand produce each bike.
Companies: Total Composite Solutions
Industries: Consumer Goods