How We Build Your Bike
A guide to our cutting edge build process…
How we build your bike
Our frames, optimised for light weight and high strength, are constructed from titanium lugs, bonded to proprietary carbon tubing. It’s a deceptively simple construction method for something that’s so cutting edge.
Learn more about the steps involved to building your bespoke bike.
The first step is down to you. Input your height, arm span and inside leg measurements to the fit calculator. Our algorithm will deliver 2 options, the closest fitting stock size (we have 3-4 times more sizes than other bike companies) or an individualised option where your frame is customised to fit you to the millimetre.
Your personal specification is output as a finished design file which becomes the brief for our RenAM500Q to print the lugs
The process is entirely digital and requires very little tooling so the lugs tailored in CAD can be built to your order.
It takes the AM machine about 16 hours to make a lug set for one bike, laying down about 3500 layers of titanium powder that’s melted by four lasers.
The lugs are formed on a single plate which is then heat treated.
Fettling and shot-blasting
Ed and Oscar remove the lug from the plate and hand finish them so each one is individually hand crafted, finally the lugs are shot-blasted for a good surface finish.
"It takes the AM machine about 16 hours to make a lug set for one bike, laying down about 3500 layers of titanium powder that’s melted by four lasers on to a titanium build plate"
Machining and Inspection
Bearing seats are machined and threads cut. It is finally inspected by a Coordinate Measuring Machine (CMM) for quality assurance.
Carbon – tubes
The carbon tubes that will make up the frame are cut to size. The tubes arrive in 3m lengths, and were designed by us for specific loads, strength and stiffness characteristics in different parts of the frame. We never bend our carbon tubing so there is no compromise on strength anywhere along the length.
To assemble the frame we use double lap shear joints which are insanely strong. We apply adhesive to overfill the joints, push the tubes in then clean the excess with 99% alcohol.
The adhesive is left to cure then the frame is checked one more time before painting; lugs are finished black or the raw titanium is protected by a lacquer before the frame is shipped to you or built up into the bike of your dreams.