Making a Carbon Fibre Bike Frame - From CAD Design to Downhill Race

[@SomeTechGuy666]

I'd like to see a video on how the bike frame was modeled so that the stress/strain/material selection could be done. Specifically, how were the various weights, layers, weaves and orientations chosen ? It is one thing to be able to lay up carbon fiber. But you can't lay it up until you know what and how much to use, where. Do different CF materials have different material models for FEA ?

[@easycompositestv]

Very fair question. In actual fact, like many bike frames, very little was done by way of FEA to determine the fibre orientation, reinforcement type and placement or fibre selection. What actually determined the layup on this frame was just a good knowledge of the basic principles (Vlad's laminated a lot of different types of bikes over the years) and then starting off with an over-engineered prototype frame which was tested and then slimmed down. FEA will give you lots of useful information and ideas but it will never give you the *full* story of how a frame will feel and so a surprising number of manufacturers use an iterative process that's a lot less scientific than you might expect.

[@sphericalsphere]

I am an engineer in the field. It is important to keep in mind what models like FEA are for: Giving you knowledge at a cheaper cost (time, effort, materials..) than prototyping. While the models/analysis to do this exist, it is a LOT of work to perform them. Way more than with metal. And with every model you have assumptions. How thic are the plys at every spot? How exact is the orientation? The joint in the middle surely isn't as strong as the rest of the part - how do you model that? is that handcut ply a little more here or there? How did it compact? cure? Was the bag a little more stiff here than there resulting in less pressure on the ply? Afterall, this isn't just a metal part where you mill out the shape you want out of an isotropic material down to .01mm or even better. Then, as if this wasn't bad enough, you don't actually know what stresses, frequencys, impacts etc you have to assume as your load. You guess, making your model inaccurate. (The point isn't to make somthing that lasts but to make something that just lasts, saving weight) But then, even worse, it isn't actually easy to say when a piece of carbon fiber is broken. First failed fiber? When something delaminates? Or only when it is snapped clean in half? What I am getting at with all those words is.. It's easier to just prototype.

[@Yaboililyeets]

@@sphericalsphere I'm a ME student in University right now and I came across this as well. Another aspect that makes FEA a little hard with composites is getting the right material properties that you mention. Most (if any) FEA and CAD softwares won't have the specific material properties to use for a test even with a perfect model. And if your were to try to calculate the material properties it would be EXTREMELY complex from my understanding. It would vary on the cross-pattern vs the UD, and the number of plys used. I made a pre-preg steering wheel for SAE mini baja and came to this realization, and decided to make a couple of prototypes. Still testing but should have it finished in time for the competition. Like you said its easier to make a prototype and strengthen or reduce where needed.

[@OoOCLUGGEROoO]

I came here looking for the same thing but wasn't massively surprised when I didn't see it. I am a PhD student looking at FEA analysis of composites and the process of taking a CAD model through to analysis in a semi-automated, structured manner and it is shockingly difficult to find any real examples of it. The reality of the situation is that it is either to expensive to do, or anyone/company who has had the money to do it isn't going to release that information because it is so valuable to them and advantageous to keep secret.

[@mzungu54]

Optimizing ply angles and layup is a tedious process... specially for something like a bicycle where there is multiple loading scenarios, and accounting for manufacturing defects, ply shifts... It's a can of worms... .. You can do it... There is a couple software like Hypersizer and such for such optimization... That's like PhD level stuff that is perform more like in the spacecraft or aerospace side.. . Best starting point of a bike... Look at other bikes. Cut up a damaged one, look at how thick the other engineer put it at various locations. Lotta of that on youtube by an Australian carbon repair guy(mostly road frames, unfortunately)... look that up.

[@tomdelvaux1262]

I, as an engineer, applied in several bike companies to be hired as a design engineer. Being told my experience in the composites field was too small to be part of the team, I decided I would design my very own carbon frame. After deciding the geometry, using Linkage, I designed the front triangle. The special idea of this frame is to assemble it from different parts, using bolts, in order to make it easily reparable and to be able to modify the geometry without having to remake an entire new design. Hope it will work. Thanks Easy Composites for the great knowledge you bring !

[@mafketeltje1988]

curious to see your project finished.....had the same idea;)

[@BrownMInc]

I hope this project is coming along well

[@mikerupe1642]

Yeah I would like to know an update. I was wondering instead of hollow tube I was watching their video of forged carbon using unidirectional strand. And was wondering if making a frame woth the chopped strand and unidirectional through the Fram and than compression mold. Which I fell would be easier instead of needing bags and pump for a hollow frame

[@LordHolley]

Would love hear/see how your journey is going.

[@widiyantosantoso_pvtm4093]

@@BrownMInc oooo

[@j6077xxd]

I just love the comment about hair and beards coming and going and then the almost immediate cut to a scene back in time and you both literally have the opposite hair and beard styles, short hair and a huge beard and mullet. Pure gold. Had me in stitches.

[@dathat555]

So much work and attention to detail. I will never again question the sky high price tag of CF bike frames.

[@illla]

You can use multiple strands of fishing line stretched across the mold to hold the prepreg edges folded during closing the mold. You close the mold partially leaving a few millimetres gap, then cut and pull out the fishing line strands and then close the mold completely.

[@javis9950]

I fail to see how you'd fasten the string enough to apply force yet also have it release on demand?

[@michalw1397]

From the differences in appearance of the Maker, beggining to end, I see how much time and work is envolved in making such a carbon beauty.

[@Bmadd67]

Watching this video was like having a magician, revealing his secrets. I have always wanted to know how a carbon fiber frame was built. Love all of these videos on the channel! Thanks

[@Beanpapac15]

Thank you so much for making these videos guys. I want you to know that these videos are a major reason why I purchase from your company. I work in a prototyping shop and we've recently acquired an oven that we plan to try with the autoclave-less prepreg system, we're excited to see how it turns out.

[@easycompositestv]

Thank you very much, that means a lot to us. It's comments like this that convince us that we're doing the right thing in making these videos and that they're helping people. Cheers!

[@LindyDesignLab]

Very interesting. Thank you for including so much detailed info and demo.

[@easycompositestv]

You're very welcome. We did wonder if this was *too much* detail but then we thought... "why not?", this is the sort of detail people appreciate on our training courses and KZbin is our worldwide training course!

[@Sickassmr]

@@easycompositestv

[@manolomonzon3646]

I been doing fiberglass for 20 years now. Im very intrigued by vacuum forming carbon fiber! This is the same method used to make the koenigsegg agera super car! This video is one of my all time favorites, thank you!

[@easycompositestv]

Thanks Manolo, we appreciate your comments.

[@danielcockerspaniel]

For those confused, they occasionally refer to molds as “tools”. In the composite manufacturing industry, molds are exclusively called “tools”.

[@CalebSalstrom]

Thank you for this clarification

[@CorwinPatrick]

Or more generally, a tool is a thing to help make another thing. The CNC was the Tool to make the Master. The Master was the Tool to make the Mold. The Mold was the Tool to layup the Carbon Fiber for the Frame halves. You might make a Production Jig (Tool) to hold the Rear Triangles in place while Bonding. And finally you may have an Assembly Jig (Tool) to hold the major pieces in place while assembling the Bike. It's all considered Tooling for the Production Process.

[@danielhatfield8921]

@@CorwinPatrick What's your point? My post was helpful, and accurate.

[@WhenDoesTheVideoActuallyStart]

@@danielhatfield8921 He just seems to provide additional clarification

[@EAGLINWRX]

@@danielhatfield8921 what’s YOUR point, he never said the comment was wrong, he made it easier to digest by providing a better analogy. Stop being a salty bastard.

[@hughobrien4139]

I’m amazed at the attention to detail and the craftsmanship put into this project. Nice work.

[@CharlieDeltaEchoVict]

Great video, thankyou. Did not realise just how much hard and skilled work is involved in these carbon frames. Great respect to you all.

[@easycompositestv]

Thanks Chris, I'm glad you enjoyed it.

[@DannyCreech]

I'm blown away with the complexity of this project. Absolutely amazing! Love your videos ECL.

[@preditorsd]

I liked it because it was a fresh video, and really well done!

[@easycompositestv]

That's great to hear. I'm glad we're getting it right on the videos *and* the customer service :)

[@skipast75]

Absolutely outstanding job gentleman. Everything about this video is 10 out of 10. The frame looks amazing and your thorough presentation are next level. Seriously the best carbon tutorial channel on KZbin, the internet... earth. I love the exposed weave and don’t understand why most carbon frames run UD on the outside now. Please do a video like this on building a wheelset with asymmetrical tubeless rims and huge conical shaped hubs. Cheers!

[@easycompositestv]

Wow, that's praise indeed. Thanks very much for the comments. Our next few tutorials will be a bit more down-to-earth, just to keep a balance, but I'm sure we'll return to some complex technology like bike components again in the future. Stay tuned!

[@skipast75]

Easy Composites Ltd I just realized something... when I first started working with carbon fiber, the first video I watched was your gun stock video. I used that method to repair a severely bent aluminum seat stay tube on a Rocky Mountain Element frame I bought for $50 on eBay. Those rear triangles were notorious for snapping in half. It worked like a charm. I pounded it out as straight as I could get it and wrapped it up with 4 layers. Wrapped the other seat stay as well. Topped it with satin clear auto paint. Ended up looking just like the better version of the same bike that came with carbon seat stays from the factory. I rode the bike hard for a season then sold it for 900 bucks. Thanks!

[@DavidG2P]

What an incredible amount of ingenuity and work going into this!

[@easycompositestv]

Thanks David, Vlad's a talented (and very nice) guy :)

[@doodskie999]

I went from yeah I will just watch this 5 mins tops to being hooked, I literally finished this 38 minute video and is now very interested in this craft

[@brawngp9443]

We use ice spray to close moulds with overlaps. It temporarily freezes the carbon and gives you a couple of seconds to easier close the moulds without trapping any material

[@easycompositestv]

That's a really interesting idea and one I've never heard before. Thanks very much for the comment and we'll be sure to test this, I can well imagine it being helpful for these difficult closure situations.

[@ExploringCabinsandMines]

adding water ?

[@Richard-fd]

Absolutely awesome!! You can see the amount of work and knowledge level that this frames requires.

[@easycompositestv]

Thanks Richard 👍

[@mrowczak1900]

Man, this frame is so beautifull...

[@easycompositestv]

Thank you!

[@NSResponder]

most elaborate part I've seen yet. Very interesting.

[@easycompositestv]

Glad you enjoyed the video :)

[@UnicornBikes]

Great video, it really shows how hands-on CF bike production is!

[@steveliggins9840]

I met Vlad at cannock chase last year and was mega impressed with the workmanship, Quantity and finish off the frame.

[@easycompositestv]

Hi Steve, thanks for the comment. You're right, this is one of those projects that you might wonder whether it looks and rides as good in real life but certainly it looks like a very nice piece of work, even under close inspection. As good as pretty much any high end bike frame does. And in terms of ride, it's being regularly raced and doing very well.

[@jeroen-surf]

Again a great video, thanks for not skipping the details!

[@easycompositestv]

Thanks Jeroen :)

[@ladraode9dedos409]

Oh boy!!!! That is what I call an instructional video! Extremely clarifying! Thanks! Thanks! Thanks! Thanks

[@easycompositestv]

Andre Demetrio, thank you!

[@tedvanmatje]

I'm a total 'noob' when it comes to this process, but it's a fascinating subject which is apparently feeding numerous nameless parts of my brain, lol I feel the need to learn more......thanks for uploading!

[@easycompositestv]

No problem at all Ted, hope you don't get a migraine from all the ideas ;)

[@FragBenitez]

@@easycompositestv hah! So you guys know from that little problem that we creative people suffer from time to time ;-)

[@MasterJeff312]

I always admire how Slavic guys are so genius at handcrafting and inventions!

[@Zohar-Modifier]

Vladimir Yordanov :) When biker made his own bike :) When swordman made his own sword :)

[@michalw1397]

You've capture the essence

[@allanknudsen2616]

I have soo much looked forward to this. Kudos to an amazing project👍👌

[@easycompositestv]

Thanks Allan, I'm glad you enjoyed it.

[@revozport]

Hi Paul, I've attended your course few years ago at your facility and I've asked you about my project in making a carbon fibre bathtub. I've finally made it with a few trial and errors. I'd love to try it with the XPREG.

[@esk8]

ohhh i would like to know more about this.

[@easycompositestv]

No way! Get in touch, we'd love to see it. And of course, if you'd like to consider making (possibly) the world's first prepreg carbon fibre bath then we'd love to be involved!

[@busagonad]

I had the honour of sitting on this beast at bmcc, what a bike 😍

[@easycompositestv]

Spencer it might have picked up an award there too I think!?

[@willbennett7107]

That was amazing as a total bike geek I would love to design and make my own parts

[@easycompositestv]

Well Will, you could start by designing and making much smaller components and develop your skills and understanding. We have customers who started off making things like crud catchers, Garmin brackets etc before moving on to more complex/critical components.

[@hashy4940]

@@easycompositestv Is it possible to cut out a mould from a piece of epoxy by hand, and then later on use a normal household oven to cure the carbon? I don't have a lot of money to buy those tools.

[@easycompositestv]

@@hashy4940 The Epoxy tooling block is very hard to cut by hand so it would be very difficult. Also it is only meant for low volume use so you may well destroy the mould after only a few pulls.

[@hashy4940]

@@easycompositestv I understand, I sort of suspected that to be the case. Anyways thank you for the reply

[@pnamajck]

that is one sick manifestation, guys … was great viewing to see all the parts coming together into the final frame … thanks for sharing the process and detail from concept to finale!

[@easycompositestv]

You're very welcome, this project was a huge amount of fun for us and a pleasure to be working with such a talented and determined guy. I'm glad you enjoyed it.

[@chriswood2674]

That's great - very informative. Would like to see the frame design process including the CAD and stress analysis etc.

[@easycompositestv]

Hi Chris, we'll have a think about what we might be able to do on that front. Vlad's already been snapped up by an established bike company and has moved overseas but there may be other things we can do to explore that side of it. In terms of stress analysis, many people would be surprised to see how little FEA influences the frame design and laminate schedule, even at the top manufacturers. There's more 'suck-it-and-see' than you'd think, especially because the 'feel' of the bike, in terms of how and where it flexes, is quite an organic process. What I can say is that the starting point for most frame designs is a basic layup that's usually *way* too heavy and strong and then an iterative process of weight reduction, tested through prototypes.

[@quinnfoster4671]

@@easycompositestv As a young aspiring engineer who has does lots of CAD design for robotics, that reliance on real world testing is pretty funny. I'd like to make some electric skateboard parts with your products after watching this!

[@doktork3406]

@@quinnfoster4671 i'd highly recommend avoiding electric skateboards having propulsion so low below the center of mass is very nasty those wheel "hoverboard" things solve that issue by automatically pitching up/down...but they can do that because they have two wheels mounted on the side having 4 wheels like a skateboard does not allow for such things..the user will fall off if power isn't very smoothly regulated, but then you lose acceleration.

[@quinnfoster4671]

@@doktork3406 I can tell you have never ridden an electric skateboard! I ran AWD maytech 6374 190KV motors, total of 7.5 KW peak power. It could easily throw you off but that was the best part, it's faster than my friends dirt bike at least on the road. Also I am working on making a DIY Onewheel out of a old onewheel v1 hub motor, as well as adding wheelie mode to an electric skateboard. Lot's of cool projects!

[@TheFoxranger]

I would be afraid to ride it. Such a piece of art !!!!!

[@atexnik]

This video is intended for those, who already understand the technology.

[@TheSubieFan]

Ya fs definitely lost but now I can go learn the technology and cross reference this video for info.

[@andya.6482]

Ya don’t say

[@Xfacehack]

Wow just a couple of years ago this would have been a case of "hang it on the wall". The fact that they basically produce something actually stronger, lighter and with this turn around is amazing!

[@Kyrazlan]

Great video! I'd love to see more of the CAD side of things like how you would sketch up a model for use with composites.

[@ScottMoyse]

I skimmed through, hoping to see some of the CAD referenced in the title... but I didn't see any.

[@thomasrimer1611]

For what it's worth, their Dark Ice sled project covers a bit of the CAD process. I'd still love to see more though, especially how he designed around the stresses involved.

[@lefthorse1]

I am blown away about that two half part stay together after cure , its that epoxy resin so strong ? I thought that there is non interrupted string traveling back and forward all along the bike frame ...

[@euroschlucker]

This channel is so extremely awesome...Keep up the good work!

[@easycompositestv]

Thank you for the kind comment! Glad you are enjoying the content :)

[@hfranke07]

Awesome project.... the transition from the cad file to the real frame at 0:30 is so awesome.... wow.

[@easycompositestv]

Thanks you, glad you enjoyed it.

[@Shrockie-]

That was awesome. Nice work Vlad! Thanks for sharing the process!

[@isaaclyonsf1]

Absolutely incredible project. I'm making a carbon fibre electric longboard in 6th form as my AS product design project and I'm using easycomposites carbon fibre and resin! Brilliant company 👍👍👍

[@easycompositestv]

That's great to hear Isaac and fab to know we're supporting the next generation of engineers! That also sounds like an ambitious project for your AS levels; kudos to you!

[@isaaclyonsf1]

@@easycompositestv thank you! Expect to see it on my KZbin in about a months time 👍

[@calebverdught]

Amazing! Thank you for posting again!

[@easycompositestv]

You're very welcome Caleb.

[@lebaillidessavoies3889]

Pretty amazing... fantastic knowledge.... the trick with the outer bag and inner bags is just brillant...

[@Micah_Makes]

Such a gold mine of small pointers and details that many might overlook. Fantastic discussion of the approach to manufacturing such a complex piece. Are there still plans for the testing and comparing various adhesives?

[@easycompositestv]

Thanks Micah, we certainly do still plan to do some comparative testing between different adhesives, yes.

[@arvismac]

I feel I'm the only one who knows nothing about the whole manufacturing process. But I love your video and how you presented it in layman's term... it made me appreciate my carbon-framed bike more now. You got a new subscriber here.

[@easycompositestv]

Hey, I'm SURE you're not the only one who this information is new too, that's how we all learn, right? I'm glad you enjoyed the video, thanks for subscribing.

[@troyd-motorsport9933]

This is amazing, Id love to do something like this, it makes you appreciate the work that goes into carbon fiber frames and why they are so expensive!

[@easycompositestv]

Yes, it's an epic amount of work when you look at the project from start to finish, but hey, it's possible.

[@jackrodgersjr]

If I owned a bike shop, I'd sit a customer in front of this video and double my price!

[@HeathenRides]

I'm no expert on composite materials but I still have a really good tip,i use to work with construction making concrete and to check the concrete mix that it's perfect we make a cube 10x10x10cm and put it in a pressure machine which loads 10kilotons of pressure on the top of the cube, you should do something similar on the prototype frames put a bar trough the hole where the Crank is supposed to be right above the bottom bracket and apply the pressure,to simulate the pressure and stress the frame recieves by bottoming out the damper/rear shock.ten kilotons ain't really that much, hundred kilo plus downwards speed can very easily become a few tons, should do a similar test on the steering tube to but apply the pressure backwards from the bottom of the fork to simulate when you land in a pothole or something with the front wheel..

[@mortarriding3913]

I've been thinking about a more "DIY" approach to this, that might involve much less machinery, for people wanting to make (usually small) frame components in home workshops, and I'd be curious what you thought of the following: 3D print (in PLA) an internal frame structure with low infill. Wrap the frame in the layers of Prepreg (bought from your store of course). Cover the outer layer of the Prepreg with some high temp silicone, or even something like a cement mix. Cook the epoxies in a temperature controlled oven, with the PLA getting drained into a tray. Feel free to poke big holes into this process if you like!

[@rreyesco]

Cool initial idea, as of 3d printing the frame but I believe it’s better not to use the prepeg carbon fiber. I think the traditional way would be better for your approach on the frame build. Because when you put it in the oven, and you mentioned the pla melting off as a release mechanism will most likely cause deformation in the CF. Heres one idea maybe.. 3d print the frame then make a negative mold out of it. Them fill the negative mold with expansive foam. Layer up the foam frame. Let that dry, then add another layer but this time using the suction pump. I think the expansive foam can be removed from the inner frame by drilling an opening and a release hole. Pouring on to it a liquid compound that would disintegrate the foam in to a sort of liquid state and easily come out the release opening hole.

[@mortarriding3913]

@@rreyesco that's an interesting idea about foam and a solvent. A similar thing can be achieved with ABS plastic an acetone. I don't understand the need for the extra step though? If you have a negative mold, why not lay the CF in that? Or why not straight away print the negative mold? In two halves ready to fill with the foam? Or similar, heat resistant internal material? I didn't think too clearly obviously about the heat treating of Prepreg, but what temp does the internal 'volume' need to resist to? I'd love it to only be two steps. And ABS can resist to 110c.

[@rubenzikarsky5195]

​@@mortarriding3913 You could probably use PVA filament. It's dissolvable in water. 1) Print an internal frame out of PVA. (Low infill, thick and smooth shell,etc) 2) Wrap your release layer and selected prepreg around frame. 3) Place in vac-bag and pull a vacuum or even another release layer and do your silicone or cement thing? Although I think a vac-bag would give a better outer finish. 4) Cook your CF. 5) Take it all off the cooked part, etc. 6) Place the CF part and internal frame into a vacuum sealable liquids bag, and fill it with a water/methanol mix (you'll have to search up best dissolve ratio) and put it in kiln at 80C for 3 hours. This will dissolve all the PVA away. 7) Take out CF part and finish it. I think this could work. Especially for small parts or custom CF as you spend less on forms, generate a lot less waste and won't have forms laying around after you've completed the part.

[@mortarriding3913]

@@rubenzikarsky5195 that's an even better idea! PVA is almost made for this purpose.

[@iliagofman]

Amazing guys! Been watching your channel for about 2 years now. Pretty cool stuff

[@capnthepeafarmer]

I'm curious how you made the mating surfaces so fine between the mold halves. They were not cut on the mold line, and it doesn't look like they overlapped after de-mold. very interested in how that was achieved.

[@easycompositestv]

The very first layer (the one you see) *was* cut completely flush with the top edge of the mould line, on both halves of the mould. This might not be clear in the video because straight after you can see more layers which are *not* cut to the edge (these are the laps) but the first layer was.

[@capnthepeafarmer]

@@easycompositestv I think I understand the process, but let me know if my understanding is correct here. The first layers on both halves are cut flush and give the cosmetic "book-matched" look. While the staggering of subsequent reinforcement layers are asymmetrical to the mold halves to provide a uniform cross section thickness. Essentially, where the staggered layers extend above the cut edge on one mold half would then have the layers staggered below the cut edge on the mating mold half. Am I close?

[@hfranke07]

Fantastic video.... I love how the tubes inside the frame can put preasure on the frame from the inside....

[@easycompositestv]

Thanks, yes, this is very much an option worth considering as an alternative to positive pressure (and safer).

[@christianmuller4027]

Very interesting video! It's hard to believe that it's more stable than aluminum. If you see all these little pieces that are glued together a little bit and that is supposed to be so stable. 😉 Thanks for sharing your video Greetings from Germany Chris

[@mortarriding3913]

What's missing when you're looking at sheets of carbon fibre being laid down, is the resin. The tackiness they referred to. It flows from sheet to sheet, creating the bonds. And because the sheets overlap, they are bonded along a large surface area.

[@xX1GuNNy1Xx]

Always wondered how complex shapes like this were made. great video that would apply to more than just bikes!

[@easycompositestv]

Hi Andrew, yes, that's right. Although it's a bike in this video there are so many composite components that are made in the same way (including classic item like composite wishbones etc.)

[@kevinhornbuckle]

You should ask a carbon fiber sex doll out on a date sometime.

[@Ekksanpher]

Fantastic video thank you! Well worth the effort, and it shows! Looking forward to the adhesive video

[@easycompositestv]

That adhesive video is in the planning and experimentation right now. Results are already looking interesting ;)

[@stevesloan6775]

I’m ten minutes in and my goodness this is some awesome engineering, bordering on fine Art! 🇦🇺🤜🏼🤛🏼🍀🍀🍀🤓🤓🤓

[@vasipro]

If you want a really good frame, make a frame from aluminium and carbon. Carbon outer layer, aluminium inner layer. This technique is used in building planes and it results in a frame both light and resilient. No more cracked carbon!

[@smartnothard2400]

I heard the T-shirts come and go and missed the haircut and beard bit. Then I was like, hold on a minute, this guy has had a haircut too! 👌 then I rewound and listened again 😆

[@Aabdallahs]

Found the channel yesterday and subbed already! I noticed you use the masking tape method to derive your ply templates. Have you considered using Fibersim or any other composite manufacturing software, or is the cost not justified right now? Or is there a reason besides the cost?

[@easycompositestv]

It can be done in software but for smaller projects and most DIY or small scale production, then it is expensive both in time and also the CNC equipment to cut the pre-preg to the CAD templates.

[@redbeard4979]

Ohhhhhhh !!!! How glad I am to see new videos on the channel.

[@easycompositestv]

Thanks Red Beard, we have two or three more in production right now so we'll be increasing our output a lot over the coming weeks and months.

[@redbeard4979]

@@easycompositestv Sir, it would be nice to make out the topic of making a carbon rim(a moto or car rim).That would be incredibly cool. You have a wonderful channel and a great presenter. I wish you immense prosperity.

[@cbpuzzle]

Great explanations. That's a crazy amount of waste bagging used. Amazing results.

[@danialhowe9814]

seen the price of a finished product? trust me they can afford the waste

[@yosyp5905]

@@danialhowe9814 How much is it?

[@aamgdp]

@@danialhowe9814 they can, but can the planet? CF is amazing material, but there's so much waste around it.

[@sepg5084]

@@aamgdp they could use biodegradable bagging if needed

[@world65tech89]

看完就知道这个项目进行了精心的铺层裁剪设计，那么复杂的拓扑，出来的效果非常赞。谢谢分享。

[@easycompositestv]

是的，这很复杂。我们很高兴您喜欢它。我们将尽快推出更多，所以请继续观看并享受

[@Lurker1979]

Just in labor. I could only imagine how pricey a frame like this would be.

[@FormerlyOn2Wheels]

Lurker1979 Your average carbon mountain bike would cost between 4-10k us. Personally I found that the golden area is about seven because anything more than that you could probably do yourself and save a few bucks anything below that don’t even bother.

[@beambox1421]

@@FormerlyOn2Wheels do yourself.... ahahahaha! let's just say that for 99.999999% of people it's not a good idea. you can try to build an F1 an it will cost you less than Ferrari to do it... but it wont be nearly as good

[@hockeyiscanada]

Lol the people that make carbon bikes are payed nothing

[@elijuvan4131]

Beambox Even I could probably make a faster formula one car than Farrari this season 😂

[@KURTrek]

My first TIG welding project was a mountain bike frame. The steep learning curve may give you nightmares, but oh boy it is totally worth the rewards. Btw, in my opinion making a carbon frame is probably 10 to 20 times as difficult as making an aluminum frame. Translating the 3D CAD file to a CNC machine (like what they showed in Step 1 lol) takes a lot of skills and equipment to do by hand. For instance, building a CNC machine that size is tough. Let alone winding the CNC servo motor stators themselves. But before that you have to melt down copper and extrude wire. I mean soon you’ll be 85 years old and wondering, why isn’t this freakin hand built servo motor still not working!? In all honesty, you don’t truly appreciate something until you’ve built it yourself. Our culture lacks this simple fact, appreciation of the fact that we stand on the shoulders of giants.

[@MikeJones-vb1me]

Wow, I now not only understand why a carbon frame is so much more expensive, but I can’t believe it’s not even more. Fascinating process!

[@easycompositestv]

Cheers Mike, yes, it's a bit of an eye-opener when you see it like this. Of course if you're making thousands not ones then you can optimise a bit (CNC cut templates etc) but even then there's still a ton of work in a bike frame.

[@MrSupermugen]

Modern Carbon frames are cheaper to manf than the comparable Alloy.

[@jacobmoore1026]

Incredible! Thank you so much for sharing your knowledge in such laymen’s terms. Cannot wait for future videos, Would it be possible to build a waterski?

[@easycompositestv]

Possibly although for sure we are going to be doing something in the future with snowboards and/or skis and that should provide a lot of the information you'll need for a waterski.

[@grasworxTTGameplan]

WaW This process is complex...but when you consider the raw cost of metal moulds and that process in rapid prototyping...this just simply blows my mind!

[@easycompositestv]

Thanks Dennis, agreed that making the composite mould is more complicated and labour intensive but you're right, it still works out an awful lot cheaper than a billet mould, which at the prototype stage might not even be right yet anyway!

[@KamenMinkov]

18:05 suddenly, a wild martenichka appears

[@drewvigne]

This is insanely informative. I will be building a composite frame for my senior design project. THANKS

[@kevinhornbuckle]

Seniors are always falling apart. They are badly in need of re-design. Focus on hips and knees, please.

[@tarekchbeir8299]

@@kevinhornbuckle That was hilarious!!!

[@yyx100]

no wonder why bikes with this type of frame is so dammmm expensive. very interesting. I hope we can fi d a way to massly produce it.

[@aamgdp]

Guerilla Gravity has some at least partially automated process www.pinkbike.com/news/guerilla-gravity-us-made-carbon-frame-smash-trailpistol.html

[@darkcrow1634]

Hi Easy Composites, easy to say the best video on youtube on how a carbon frame is made! I'm new to the carbon frame world, and there's a little confusion that's bugging me. Compared to the technique of having carbon sheets stick onto an EPS frame, how would these pressured tubular bags compare? Does it give better inside surface? Does it help with weight reduction?

[@easycompositestv]

Hi Tigor, using the foam core method is likely to produce a heavier frame if it had the same strength as one produced in a mould. Both the inside and outside faces of the tubes would be less straight (more wobble) which reduces strength and leads to extra weight once thick coats of resin or clear coat are added to correct the surface. You also have some extra weight from the core. That said, it is a less complicated and expensive way to have a go at making a frame. One of our customers did a beautiful job of a similar process.

[@DebaJ99]

I thought he was joking when he was talking about haircuts and beard trims in the beginning.

[@easycompositestv]

Not as all. I think our channel is getting a reputation for almost being able to count the years through Paul's haircuts, they're a pretty-much annual thing!

[@kevinhornbuckle]

Hair styles were harmed in the making of this movie.

[@LeviewFPV]

This channel should have millions of subscribers! amazing content!

[@easycompositestv]

Thanks Frederico, we'll settle for 100k *quality* subscribers!

[@jansvasta2146]

So that is why they are so expensive! All the labour, it makes sense now.

[@xDarkAngelxc]

Exactly and here I am thinking it was mostly the carbon fiber that was expensive! Most of that money is probably going to labor.

[@easycompositestv]

Definitely for a business, labour costs are a considerable factor. Hence why often the labour costs saved using pre-preg materials on complex parts more than offsets the extra material cost.

[@djremotion2]

I have waited for new video from you for 2 years. Always interesting. Thanks! :) In Finland bikeframes are done a bit differently. 3D print the inside of the frame, then just lay the carbon around it everywhere, and then dilute the 3D-printed part away from inside, so it is eventually hollow. Not my business but just know how they operate that.

[@easycompositestv]

Thanks for the message, you’re absolutely right that you can indeed make a prototype frame using the sacrificial core method. There are a number of reasons why the conventional method of having moulds produces a superior result but sacrificial cores are defiantly interesting and have their place, especially for prototyping and development work. We have a customer in France who did a great project this way and we might do a video in the future demonstrating this technique.

[@djremotion2]

@@easycompositestv In meanwhile I need to order you some perma-grit stuff that I forgot from last order. kinda wasteful to pay 15€ postage on a 5€ sawblade, but that's how it is.

[@rubenbaca9529]

32:36 wasn´t he hitting the frame ? :o

[@huon7906]

The insert he was knocking out had 2 halves, he was hitting the second half.

[@EMUPCGames]

Insane video. So instructional, clear and easy to undestand what is the process or steps behind bikes frame. Perfect 😎💥

[@easycompositestv]

Haha, thanks. Now you know what to do!

[@Stevensherah]

When you said hair cut I didn't think it was 1:45

[@easycompositestv]

You were warned ;-)

[@dp5475]

That was a friggin sick mold. Well done

[@tomrush08]

Why does vlad keep looking into the camera like a kidnap victim

[@easycompositestv]

You’d have to ask him. He’s in our basement.

[@kevinhornbuckle]

He had a sinking feeling they were going to make him cut his hair.

[@watchere]

Amazing video as usual, there is a new found appreciation for how much work goes into these carbon frames!!

[@easycompositestv]

Hi Jason, yes, sometimes even when you may have no direct application for this knowledge yourself, it's still really good to know what work and processes do go into these things.

[@watchere]

@@easycompositestv I absolutely agree, I have seen other videos of the Trek factory making these, and thought this would most likely not obtainable with out large machinery. Though, still extremely complicated, and painstakingly labor intensive, its good to know with time and determination you still can produce a beautiful product that looks production ready!

[@donchristie420]

I’m still at that stage of alloy or carbon- alloy or carbon, I’ll bend alloy- god, what would I do to fuck up carbon

[@peetermauring8732]

6:13 Those mini wrenchs are so cute

[@hansdietrich83]

Very nice, but you skipped some of the most interesting parts, like designing and planning the cut patterns and removing the bags from inside the frame

[@easycompositestv]

Thanks Hans. Removing the bags from the inside of the frame wasn't too exciting, we really did just pull them out through the neck. I think we were conscious that this was already a 40 min video! As for planning the cuts, we did film lots of this but it was difficult to make sense of watching it back. Planning the cut lines and orientation for the surface ply was mainly considering the visual appearance and making the two sides symmetrical. The main reinforcement we tried to explain in quite a lot of detail but I guess there's always more detail we could provide. If you're doing a similar project and have any specific questions, please get in touch with us.

[@Oelngatikameie]

@@easycompositestv Could you make a tutorial how to make this frame, but from desiging the pattern, to put all layers and finishing works (maybe with 3-5 40minutes parts video?)with discussing everything ?

[@stanislav6668]

John Snow acting Vlad is very professional

[@rph32gtr]

Should of just let the guy building it talk, looked like he was just standing there hoping he would shut up and let him do it 😂

[@FOOKYOUTUBENUMBERS]

I now I felt bit uncomfortable, He started stirring straight down camera He was that bored

[@danjennings5068]

Issue is the people that are good at designing/accomplishing something aren't always good at explaining what they're doing and why.

[@FOOKYOUTUBENUMBERS]

@@danjennings5068 Totally agree with this Comment, and can relate to it, like Many others will

[@ukpkmkk_2]

Should HAVE*

[@FOOKYOUTUBENUMBERS]

@@ukpkmkk_2 Or should've

[@ramonbs6075]

This is gold! Applause to the editor as well!

[@easycompositestv]

Thank you for the kind comment!

[@johnnyVGtran]

can't imagine how much that bike retails for lol

[@69mjar]

Anywhere from 10k to 15k I'm sure.

[@farhanmashrur7982]

$19000

[@WhenDoesTheVideoActuallyStart]

Yes.

[@groomlake51]

This was AWSOME and I work with composites every day🙏🏻

[@easycompositestv]

Thank you for your kind comment!

[@Bimar1986]

This is like engineering/manufacturing porn

[@cromptank2424]

19:48 - I’d assume a big reason to stagger the layer overlaps is because the fibers aren’t continuous across the mold halves creating a stress concentration in the resin matrix. Offsetting each layer’s overlap region prevents concentrating all the weakness into a small area, letting you get avoid unnecessary bulk on that seam.

[@easycompositestv]

Yes, that's exactly what's happening and the reason for it. The only real strength comes from the fibre, the matrix is just there to lock the fibres in position. Without fibre overlapping the join, the frame would crack open like a Kinder egg!

[@crimsonram77]

That guy talks to much I just wanna see steep by steep 💀

[@mentho101]

I see, you are not a true mountain biker

[@kevinhornbuckle]

Steep demand, dude.

[@hockeyiscanada]

Hello, I jump with joy when I seen this video showing how to make a bike frame from beginning to end, especially since I was goung to buy equipement from you guys !! Great job guys !! I was woundering if you guys know any good CNC machines (for one's home) able to make molds with Epoxy mod boards for a bike ?

[@easycompositestv]

Hi Yoan, thanks, we’re glad you like it and of course we’d love to have you as a customer. Regarding a CNC machine, it really depends on your budget and the size of the bed you want. Although it’s a bit less convenient, it’s often worth considering a smaller bed than required and then join sections of the pattern together. When you’re looking at larger machines they are disproportionately expensive because doubling the travel tends to mean 4 times the gauge of steel etc in order to maintain accuracy/stiffness in the machine. Obviously Vlad used a high machine in this video but something much smaller would be fine for home use. We have a low cost desktop machine made in China and badged as “CNC EST” and it’s worked superbly since we had it. Hope this helps.

[@hockeyiscanada]

@@easycompositestv Thanks for the awesome answer, that helps a lot. I'm not sure I would trust a mold as wide as one for a bike frame put together in pieces, that might be complicated having to stick it together and make it smooth inside so no marks would come out on the outside of the frame, you know what mean ?

[@shanghaimetricsleadinstrum4487]

thank you very much for posting this video .i wonder what would be the Mass production line looks like for this kind of product

[@xerifenomade]

beautiful project, exquisite work, i watch all the videos and today i understand why the value is high, matrix design template preparation everything very calculated in details, wonderful

[@easycompositestv]

Thank you Wegner, we appreciate your comment and feedback :)

[@jeanfrancoispoivre4438]

Superbe vidéo, j'espère une autre bientôt.... merci à Easy composites

[@easycompositestv]

Vous êtes les bienvenus Jean, surveillez cet espace!

[@sanjayheaven5230]

I would really appreciate seeing the process more than hearing it

[@easycompositestv]

No problem, just turn the sound off 😉 👍

[@sanjayheaven5230]

@@easycompositestv I didn’t mean like that 😂😂

[@davidtlchow]

Value information contains in this video for teaching people making structural carbon parts. Thanks.

[@k.g9863]

How do you get the cad model onto stets of Carbon fiber? How do you transform 3d into 2d and how do you know how many lies to put where and what stiffness or regidity you need where?