Felt Bicycles Technology

CARBON FIBER MANUFACTURING METHOLOGY

MANY FACTORS INFLUENCE THE MAKING OF A GREAT FRAME, FORK, OR COMPONENT.
DESIGN DETAI LS, CONSTRUCT ION METHODS, AND MATERIALS ARE THE PRIMARY THREE.

DESIGN DETAILS
Carbon Fiber is an engineer’s dream come true: A material that is lighter than aluminum and is pound for pound stronger than steel. It can be molded into complex shapes and sizes, as well as having the ability to be “laid-up” with more material where you need it, and less where you don’t. By utilizing this material, we are able to take our wall specifications and tube shapes to the next level. Some of these details include oversized diameters, unique shapes, and exaggerated tapers. Every frame implements size-specific details. For example: the tube diameters of a 50cm frame are noticeably smaller than the tubes on a 60cm frame;
even radii and tube transitions change to support areas of the frame differently. All of this adds up to a frame that is stiff and responsive, yet has excellent damping characteristics and vibration control, specific to the needs of a given size rider.

CONSTRUCTION
All Felt carbon frames are created using our Modular Monocoque Method - the second major factor contributing to a frame’s performance. This is a process in which the front triangle, seat stays, and chainstays are molded as individual sections. This allows us to completely optimize each frame section
toward a specific requirement; be it torsional stiffness for the front triangle, or vertical compliance in the seat stays. Each of these frame sections is made of multiple layers of carbon. The number of layers is not constant along the entire part: in areas where the load on the frame is high, more layers are used; and in low stress areas, fewer layers are used to save weight. After these individual sections are created, they are fused together into a seamless monocoque (one-piece) structure. Since carbon fibers work best in tension, when assembling the carbon parts we carefully position the unidirectional carbon cloth so that the fibers are
oriented in the direction of greatest stress. Unidirectional carbon fiber has the highest tensile strength, and is used for the structure of the frame. The Modular Monococque construction method is superior to other processes due to the unified design which ensures perfect alignment, no excess material, no need for putty
or filler in the finishing process, and no stress concentration; all while delivering minimal weight, amazing responsiveness, and incredible overall strength.

MATERIALS
All carbon fiber material is not created equal. Simply looking at the properties of a single material is no way to judge a frame’s quality. The carbon weave, or outer appearance, which most people recognize is typically used only for the final outermost layer, which is visible through the clear coat. Although this lends
some structural integrity to the frame, it is primarily cosmetic. So a 2K, 3K, or 12K weave designation does not necessarily determine a frame’s quality.

Carbon Fiber can be ranked in two ways: one being the Modulus, which dictates the fiber’s relative stiffness; and the other being Tensile Strength, or how strong or tough the material is.
Building a frame of just the highest modulus material would be a disaster, as the ride quality would suffer from being too stiff, as well as the overall strength being compromised. The key is to blend different materials with unique properties, placing them in specifically targeted areas of the frame. In doing so, we can tailor our frames to possess just the right combination of stiffness, strength, and compliance while achieving a desired weight.

ALL OF FELT’S CARBON FRAMES USE ONLY THE HIGHEST QUALITY, PREMIUM NAME BRAND CARBON MATERI - ALS, AND IT IS HOW WE BLEND THESE DIFFERENT TYPES OF MATERIAL WHICH IS THE THIRD MAJOR FACTOR IN OPTIMIZING OUR FRAMES. HERE IS A LOOK AT THE THREE DIFFERENT CARBON MATERIALS AND BLENDS FELT EMPLOYS THROUGHOUT OUR B ICYCLE LINEUP:

HIGH MODULUS:
The carbon fiber in our High-Modulus frame material is a T700-based blend, and has a tensile strength 7.9 times greater than 3/2.5 Titanium, and stiffness 3.34 times greater than 6061 Aluminum.

ULTRA-HIGH MODULUS:
The carbon fiber used in our Ultra-High Modulus is a M30S based-blend and is 27% stiffer than material used in our High Modulus frames. Ultra-High Modulus material has a lower capacity for retaining resin, which results in a frame roughly 20% lighter, yet with virtually identical stiffness and strength.

ULTRA HYBRID CARBON (UHC):
For frames utilizing our Ultra Hybrid Carbon, we source materials from several of the world’s leading carbon fiber manufacturers. We select the optimal blend of three different fiber types (SB60, M30S and T700) and
strategically locate them based on their unique attributes; using the toughest carbon fiber in a given area and the stiffest carbon fiber in another, delivering a chassis with unmatched compliance, lightweight, strength, performance and handling.

When it comes to our carbon fiber manufacturing methodology, it goes without saying that an incredible amount of design, testing, experience, and cost goes into the development of each Felt frames and component. The result is a frame free of compromise and full of performance; providing you with the ultimate ride, and the ultimate advantage.