Carbon

Race Frames in Layered CARBON

Carbon fiber has now become the most commonly used material for the construction of high-end bicycles. All production is carried out in Italy, as our country boasts some of the finest carbon fiber manufacturers. These companies, due to their proven technical expertise, count brands such as Ferrari and Ducati among their clients.

For each Formigli model, specific tubes are produced based on the quality segment of interest. The first step in the frame construction is undoubtedly the design, which outlines the shape of the object to be created, constantly assessing its faithful alignment with the original idea through a 3D model.

Next, with the consultation of a carbon fiber technician, the profile and performance of each tube are carefully examined to determine which variant of this material is most suitable for use. With this system, after testing tubes of various shapes and pairing them with various carbon fabrics, we achieved high torsional rigidity across the entire range. To configure a strictly “custom-made” frame, particular and precise information about the cyclist’s style and physique is required, ensuring a unique, personalized bicycle down to the smallest detail. The customer’s measurements are crucial to ensuring the best performance and rideability of the bike. After the design phase, the actual manual process begins: the tubes are milled and then placed onto the construction jig. Following the pre-assembly of the frame with a sealed bonding process, the “vacuum carbon layering” begins, a system that allows us to create a frame much stronger than other methods. Finally, the joints are meticulously polished and finished by hand.

These procedures are the essential characteristics of Formigli products, which require particular care and great craftsmanship. The tube-by-tube construction process ensures a perfectly customizable frame and allows the use of any type of carbon fiber, depending on the application and design of the bike. Once the work is completed, the graphics and color are developed together with the customer, who can rely on the expertise of our painting process, where each frame is carefully followed from start to finish, ensuring a unique product for our clients.