Professional Documents
Culture Documents
FACT CARBON
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The headline is that the 2010 Epic is a better bike than weve ever seen. What Mountain Bike Magazine No pedal stroke is wasted on the climbs and no extra energy is needed to control the bike on descents thanks to an incredibly stiff front triangle, nearly perfect suspension and flawless handling. Bicycling Magazine
EPIC REVIEWS
This bike makes no apologies and doesnt need toits that good. Philip Booth, Road Bike Action Magazine
WINS
2009 Liege-Bastogne-Liege Multiple 2009 National Championships Winner Stage win and 2nd place overall, 2009 Tour de France
WINS
2009 U23 World Championship 2009 XTerra Cup Series 2009 Sea Otter XC 2009 Pro XCT Team Classification 2008 XC World Championship Bicycling Magazine Editors Choice Award, Best Performance XC Mountain Bike Bike Magazine Germanys Most Innovative Bike Award 2009 International Constructors Award
Not only did this carbon bike receive higher marks for climbing and handling than most of the race bikes we tested, it also dominated the comfort category. Dont be fooled by the word comfort, though. This is an elite racer ... already proven in europes grueling cobbled classics. Marc Peruzzi & John Bradley, Outside Magazine
ROUBAIX REVIEWS
The Era is easily the sweetest freakin bike Ive ever ridden. Ive been doing some epic days on it, and its just killer. Love, love, love it. Selene Yeagar, contributor to Bicycling Magazine The Era is a capable descender that truly shines on the climbs ... If youre a female racer searching for a bike specially built to meet your competition needs, the Era is the bike youve been waiting for. Mountain Bike Action
ERA REVIEWS
WINS
2x Winner Paris-Roubaix 2008 Paris-Roubaix 2009 Paris-Roubaix
WINS
2009 XC World Cup #6; Bromont, Canada 3x Winner 24-Hour Solo World Championship
If I could only use one word to describe the Shiv, it would have to be fearsome. The Shiv looked like it was irritated to be standing there stationary, displayed on a table. - Neil Browne, Road Magazine Riding the Shiv, I consistently had the feeling that the bikes limits were beyond my physical abilities. The bike is designed for the fastest time trialist in the world and it shows. In the hands of Cancellara, the Shiv will cut a straight line to the top of the podium. Philip Booth, Road Bike Action Magazine
SHIV REVIEWS
The most technologically advanced cross-country hardtail race bike that we have ever had the pleasure of throwing a leg over. This bike doesnt accelerate as much as it explodes. Both from mbaction.com
STUMPJUMPER REVIEWS
WINS
2009 TT World Championships 2009 Danish National TT Championships Prologue and final time trial, 2009 Tour de Suisse Stage win, 2009 Tour de France Prologue and stage win, 2009 Vuelta a Espana Stage win, 2009 Tour du Poitou Stage win, 2009 Eneco Tour
WINS
2009 Sea Otter Short Track Womens 2009 Leadville Trail 100
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SAXO HAD SPECIFIC STIFFNESS REQUIREMENTS AND WANTED SOMETHING SLIPPERY FAST. OUT WITH CONVENTIONAL AERO TUBING, IN WITH ALL-NEW DESIGN CONCEPTS. THIS REQUIRED RADICAL ENGINEERING OF ALL TUBE SHAPES. FRAME SHAPE
SAXO ASKED FOR AGGRESSIVE AND FAST. WE LARGELY DESIGNED AROUND FABIANS GEOMETRY AND HANDLING CHARACTERISTICS FOR THE XL SHIV, THEN ADAPTED THE TECHNOLOGY FOR OTHER FRAME SIZES. GEOMETRY
SAXOS STIFFNESS AND AERODYNAMIC DEMANDS WERE ONLY ACHIEVED THROUGH SYSTEMS INTEGRATION OF COMPONENTS LIKE THE HEAD TUBE, STEM, BRAKES, BB, AND CRANKSET. NOTE THE SEAMLESS DESIGN OF STEM, STEERER, AND FRONT BRAKE. SYSTEM INTEGRATION
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CARBON-CENTRIC DESIGN
We approach the engineering of our tube shapes and joints through a concept we like to call carbon-centric design. Carbon can be molded into just about any shape with proper engineering, but by designing tube shapes with the properties of the material in mind, we can create a much more optimized structure. On its own, carbon fiber only possesses tensile strength. But when a flat sheet of prepreg (resin-impregnated carbon) is cured, it gains some compression strength and some bending strength. So by properly layering these prepreg sheets during the bikes layup process and utilizing the carbon in an efficient geometric shape, we can create tubes that are capable of resisting tensile, torsion, and compressive forces, all of which we encounter while riding. The real science lies in the ply angles of the carbon. Zero-degree carbon plies work to resist bending and +/- 45 degree angle plies resist torsion. When twisted, either the + or - 45 degree fibers are in tension (depending on the twisting direction), but when bending, one side of the tube is in tension and the other in compression. Long story short, by putting as many fibers as possible in tension (carbon is at its best when its in tension), we can create a stronger, stiffer bike. This is why its fundamental for us to know the ratio between bending and torsion in each tube. Beyond the properties of the material itself, here are the other considerations we make in carbon-centric design: Carbon fibers arent as strong when bent at extreme angles, so our engineers focus on eliminating sharp corners, creating smooth transitions, and utilizing large radii tubes. To maximize structural properties such as strength and stiffness, our engineers use frame and tube geometry to their greatest advantagean example being the Tarmac SL3s large down tube and bottom bracket junction, which helps the bike achieve a superior stiffness-to-weight ratio. We eliminate the need for extra carbon material (which other manufacturers might use to build in a margin for error to account for less-than-precise manufacturing) by making our tooling, layup, and molding processes as efficient as possible. Our hard work early on in the design process is what allows us to make frames and components of such consistent quality.
We design and optimize each tube size for each frame size. Here we show down tube sizes.
Beyond just aesthetics, the shape of a carbon frame or component has a huge impact on how it will perform. Smart tube shapes dont just happen; they are the result of months of R&D, field testing, and years of experience riding previous models, including those of competitors. Here are the factors we consider when optimizing tube shapes:
STRAIN GAUGING Allows us to determine the ratio of bending vs. stiffness in each tube and to compare the relative importance of those tubes in different stiffness scenarios.
stiffness load cases or a combination of both. Full frame studies show the effect of triangulation in the front and rear triangles and the effect of a bowed top tube on compliance.
FEA STUDIES Through this computer modeling software, we can isolate different tubes for pure bending or torsion
EXPERIENCE Simple. We watch how tubes deform in dynamic and static fatigue tests and make modifications based on our
findings.
TUBE LOCATION Our tube shapes are designed to resist specific forces, depending on their location. We shape the top tube differently than the down tube, for example, because each tube sees more or less loading, plus a different ratio of bending and torsion stress, depending on the riding scenario (e.g. sprinting, descending, etc.). FRAME SIZE The way we see it, different frame sizes warrant different tube sizes. If we didnt design each tube in this manner, a larger frame would have inherently lower stiffness due to the length of its tubes (meaning they flex more than a short tube under the same load). And at the same time, larger riders are capable of applying more force on their bikes. This makes determining the appropriate level of stiffness for each size bike/rider extremely important.
By designing the top tube, down tube, seat tube, and seatstays for each frame size, we can accurately and efficiently control stiffness variables from our smallest to largest frame sizes. Though size-specific tubes require much more work from the engineers who have to painstakingly design each tubeset, the result is a proportional range of bikes with consistent ride qualities across every platform (e.g. Tarmac, Roubaix, Amira, etc.).
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MATERIALS SELECTION
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MATERIALS SELECTION
THE PROCESS BY WHICH WE SELECT MATERIALS FOR OUR FACT BIKES AND EQUIPMENT
FIBER SELECTION STIFFNESS (E) AND STRENGTH (Y) FIBER TYPES RESIN SELECTION TOUGHNESS TEMPERATURE RESISTANCE
A cut-away of our tapered crown design. U.S. patents 7, 520,520 and 7,537,231
Carbon-centric design doesnt stop at frames; every component we create, including our FACT carbon forks, follows the same design philosophy. Traditional fork designs use a large flat crown surface as a seat for a standard crown racea design borrowed directly from alloy and steel forks. However, since this shape demands 90-degree changes in geometry, it diminishes the effectiveness of the carbon fibers (considering, as we said before, that carbon is strongest in tension). In 2007, we introduced our first tapered crown/raised bearing design and put it on our Roubaix bike. The tapered section of the crown accommodates the bearing and allows the carbon fibers to flow smoothly between blade, crown, and steerer. By virtue of its geometry, tapering also provides a stiffness/strength advantage that we can prove through FEA studies. Finding this design to be widely successful, weve since applied it to all of our FACT full carbon forks, and now, we even use raised bearings on the majority of our carbon mountain bikes. Fork strength and stiffness are, without question, two of the most important attributes of the bike and something we really focus on during development and testing. Strength aside, stiffness is what makes your front wheel track well when cornering and descending, so its paramount to the quality of your ride. By increasing both lateral fork stiffness and steerer tube torsion stiffness, our tapered crown design creates a more confident handling bike.
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MATERIALS SELECTION
MATERIALS SELECTION
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FIBER TYPES
FACT RATING MATERIAL MANUFACTURING METHOD FINAL LAYER
TARMAC
S-WORKS TARMAC SL3 TARMAC PRO/EXPERT SL TARMAC COMP & ELITE FACT 11R FACT 10R FACT 8R E630 E390 E240 FACT IS FACT IS TRIPLE MONOCOQUE UNI 12K 12K
ROUBAIX
S-WORKS ROUBAIX ROUBAIX PRO & EXPERT ROUBAIX COMP & ELITE ROUBAIX (BASE) FACT 10R FACT 9R FACT 7R FACT 6R E390 E285 E285 E240 FACT IS FACT IS TRIPLE MONOCOQUE TRIPLE MONOCOQUE UNI 12K 12K 12K
Modulus is an engineering term for fiber stiffness. Though high modulus carbon is good for stiffness, it tends to have lower elongation at failure. In general, you wouldnt want to build a whole frame out of high modulus material, so we hybridize (mix) our high modulus carbon with a number of other materials and in varying modulae (stiffness ratings) to make our frames as light and stiff as possible without sacrificing strength or durability. The general idea is to align the higher strength material with loads and to save as much weight as possible everywhere else with stiffer high modulus material. Pitch fiber is nearly double the stiffness of high modulus fiber, but lacks strength compared to lower modulus materials. Its also very expensive and difficult to manipulate. Because of this, we use it very sparingly and strategicallyonly on S-Works bikes like the Tarmac SL3 and Epic and only in places that will benefit the most from a major boost in stiffness. Rated at 40 Ton or 57Mpsi (millions of pounds per square inch). Thats about 62% stiffer than the standard aerospace-grade material most carbon bicycles use. At triple the cost of standard modulus fiber, this fiber is used extensively in S-Works and Pro-level frames. Used to maximize strength and keep weight low in the highly stressed parts of the frame, like the top and down tubes. Because of its relatively high modulus and superior strength, this material is a good all-around workhorse for premium composite frames. Intermediate might not sound like the pinnacle of technology, but dont be fooledthis material has an optimum blend of stiffness and strength to make your bike as damage-tolerant and stiff as you expect it to be. Aerospace-grade carbon fiber used in conjunction with other materials for improved impact strength in specific areas. Note: Some companies call any aerospace-grade material high modulus when, in fact, its industry standard modulus material.
RUBY
RUBY S-WORKS RUBY PRO/EXPERT RUBY COMP/ELITE FACT 10R FACT 9R FACT 7R E390 E285 E240 FACT IS FACT IS TRIPLE MONOCOQUE UNI 12K 12K
HIGH MODULUS
AMIRA
AMIRA S-WORKS AMIRA EXPERT/COMP FACT 10R FACT 8R E390 E285 FACT IS FACT IS UNI 12K
INTERMEDIATE MODULUS
MOUNTAIN
S-WORKS HARDTAIL SJ MARATHON & EXPERT HT S-WORKS HARDTAIL, 29ER SJ MARATHON & EXPERT HT , 29ER S-WORKS EPIC EPIC MARATHON & EXPERT S-WORKS ERA ERA EXPERT S-WORKS SJ FSR S-WORKS SAFIRE STUMPJUMPER FSR PRO & EXPERT SAFIRE EXPERT S-WORKS ENDURO ENDURO PRO
FACT 10M FACT 8M FACT 10M FACT 8M FACT 11M FACT 9M FACT 10M FACT 10M FACT 10M FACT 10M FACT 8M FACT 9M FACT 10M FACT 9M
Y579 Y579 Y579 Y579 Y579 Y579 Y579 Y579 Y579 Y579 Y579 Y579 Y579 Y579
TRIPLE MONOCOQUE TRIPLE MONOCOQUE TRIPLE MONOCOQUE TRIPLE MONOCOQUE FACT IS FACT IS FACT IS FACT IS FACT IS AZ1 FACT IS AZ1 FACT ISX FACT ISX
UNI 12K UNI 12K UNI 12K UNI UNI UNI UNI 12K 12K UNI 12K
STANDARD MODULUS
TRICROSS
S-WORKS TRICROSS TRICROSS PRO FACT 10M FACT 10M Y579 Y579 AZ1 AZ1 UNI UNI
TRANSITION
S-WORKS TRANSITION PRO, EXPERT & COMP TRANSITION FACT 9R FACT 7R E390 E285 TRIPLE MONOCOQUE TRIPLE MONOCOQUE UNI 12K
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MATERIALS SELECTION
FABRICATION PROCESS
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WEAVE TYPES
UNI-DIRECTIONAL
PROS
MOST EFFICIENT USE OF MATERIAL BECAUSE FIBERS REMAIN THE STRAIGHTEST
A STEP-BY-STEP GUIDE
TO FACT CARBON MANUFACTURING
STEP 1: TOOLING
CONS
DIFFICULT TO GET PERFECT COSMETICS
WHERE WE USE IT
ALMOST EVERYWHERE ALL FRAMES USE UNI-DIRECTIONAL FIBER FOR THEIR MAIN STRUCTURE
3K OR 12K WEAVE
The first step is for us to create a custom-made steel mold that defines the exact outside shape and surfaces (the part of the frame you can see) of the frame. Depending on the part its being created for, a steel mold may take 8-12 weeks to make. Why so long? Because its a big chunk of steel thats precision CNCd, weighs a few hundred pounds, and must be accurate to within a few thousandths of an inch in every aspect. A finished frame section or part comes out weighing just a tiny fraction of the tool. Assuming the mold is made correctly, the finished part will have the same level of accuracy as the mold. In this important step to the manufacturing process, flexible sheets and pieces of prepreg are wrapped over a pre-form mandrel and assembled into the shape of a frame, fork, or part according to a heavily revised Layup Schedule Development (see page 16 for details). Arguably, a pre-form can be anything; a round tube, the nylon bladder used to mold the frame, or even just a piece of wood. But in the case of our highest end bikes, we want the pre-form shape to mimic the shape of the mold cavity as closely as possible. So we take the time to engineer a mold for all of our pre-forms and invest in the tooling required to make some of the most advanced mandrels used in the composites industry. These super accurate pre-forms allow us to mold very complex shapes (like the Shivs seat tube or the bottom bracket of the Tarmac SL3) and optimize fiber alignment, which is key to achieving the ultimate in stiffness. Next, we place an air bladder made of pressure-resistant nylon inside the flexible composite layup structure. Its function is to internally pressurize the composite material in the layup against the tooling surface to eliminate internal voids in the composite structure. By using silicone lining in conjunction with the bladder during molding, we can ensure adequate compaction in areas with complex geometry. Still pliable, the entire prepreg assembly, including the bladder, is placed inside its big steel mold. The multi-piece mold is closed and locked down, and the bladders are connected to pressurized air fittings. The closed mold moves on a conveyor into an electric hot press where its temperature is raised to 155 c (thats 311f or 428.1 K.) The high temp allows the resin in the prepreg to liquefy and spread uniformly in the composite layup. To help aid in the process, the bladders inside the prepreg assembly are pressurized to 150 psi. This mixing of resin in the carbon fabric is called wet out, a critical component to the integrity of the molded structure. Too little pressure in the bladder and the composite wont wet out effectively, leaving high-resin areas that add useless weight and low-resin areas that weaken the structure. Too much pressure and the resin gets squeezed out of the composite altogether. Correct wet-out pressure forces between 4% and 8% of the resin out of the prepreg. Note: Some manufacturers claim ultra-low resin content. This is not good! The mold stays at this temperature for about 30 minutes depending on its size, then it must cool down. Due to the size and mass of the steel tooling, this takes another 20-30 minutes. Once the frame inside the mold has cooled enough, the resin is cured and cannot be changed. If there is even a minor defect or issue with alignment, the entire frame must be scrapped. These types of unchangeable composite structures are called thermoset; structures made with a different matrix that can be re-heated and changed are called thermoplastic.
Cured composite section (top tube, down tube, head tube) after molding
IN DAMAGE-PRONE AREAS
TWILL WEAVE
BB pre-form mandrel and resulting carbon fiber layup ready for molding
STEP 3: MOLDING
PREPREG MANUFACTURING Prepreg is defined as flexible sheets of carbon that have been impregnated with resin. During the layup process, these sheets are strategically layered into pre-form shapes before getting baked in a mold. Unique to Specialized, we make our own prepreg from both uni-directional and woven materials, even weaving our own fabric. This allows us to control exactly what goes into our bikes, from the fiber to the resin content to the process by which the prepreg is manufactured.
We use the hot melt process for making prepregthe most sophisticated method available.
After determining the appropriate materials selection for each family of bike (and even each bike size within that family), our engineers use 100+ pieces of carbon fiber to create specific carbon layups that yield the perfect combination of stiffness, compliance, strength, and weight. Whether its the super stiff Tarmac or more balanced Roubaix, we can optimize performance for any given experience.
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FABRICATION PROCESS
FABRICATION PROCESS
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FACT IS
FACT IS Method
TRIPLE MONOCOQUE
MOUNTAIN Stumpjumper HT S-Works, Marathon, Expert, and Comp models; Stumpjumper HT 29er S-Works and Expert models
Note: For 2010, the S-Works Tricross and Safire S-Works and Expert models still utilize our Az1 manufacturing method, but FACT IS is becoming the more prominent construction for our high-end bikes.
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500
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2500
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2047 2049 2101 2119 2244 2271 2271 2280 2285 2302 2500 2559 2674
(N*m/deg)/kg)
LAYUP DESIGN
2010 TREK MADONE 6 SERIES 2009 GIANT TCR ADVANCED SL ISP
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
124.3 111.2 104.6 99.8 93.7 90.5 84 77.2 76.6 74.5 74.5
HIGHEST RATIO
LAB STIFFNESS
LAB STRENGTH
2009 RIDLEY NOAH 2009 PENARELLO PRINCE 2010 PENARELLO DOGMA 60.1
FINAL LAYUP
2010 TREK MADONE 6 SERIES 2010 PENARELLO DOGMA 60.1 2009 CERVELO SOLOIST SLC-SL 2009 CANNONDALE SUPER SIX
71.8 70.5
LOWEST RATIO
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STIFFNESS-TO-WEIGHT BB TESTING
Just like torsional stiffness-to-weight, a higher number indicates greater stiffness. Generally, the stiffer the structure is to the riders pedaling forces, the faster the frame will respond to rider acceleration. With the SL3, we shot for a high stiffness number, then focused on maximizing torsional and rear triangle stiffness, while reducing weight. For this test, each frame is fixed at the head tube and rear dropouts and angled slightly to simulate the side-to-side motion of a bike during heavy sprinting loads. Weights are applied at the pedal through a simulated crank arm and chain at the power-stroke position, then the deflection at the BB is measured and the results are divided by frame weight.
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
(N/m)/kg
57.9 55.5 50.7 50.7 48.9 48.3 46.6 45.1 42.9 39.6 38.8 36.7
STIFFEST
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
180.0
200.0
6 COMPLIANT
2009 CERVELO R3 SL
5.14 4.55
HIGHEST RATIO
2008 CERVELO RS
2.56
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
2009 CERVELO R3 SL
STIFFEST
125.2 110.8
100.8
2009 RIDLEY NOAH 2009 CERVELO SOLOIST SLC-SL 2010 TREK MADONE 6 SERIES
33.7
LEAST STIFF
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50
100
150
200
250
100
200
300
400
500
600
700
800
900
597 603 742 750 610 760 632 770 695 799
LIGHTEST
STIFFEST
SRAM RED TIME ASX TITAN CARBON BONTRAGER RACE X LITE CAMPY RECORD UT FSA SL-K STANDARD
148.8 136.3
LEAST STIFF
HEAVIEST