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TECHNOLOGY

We design high-quality, high-performance bicycles using industry proven techniques, with the best materials available that offer better riding experiences. Learn more about how we design, fabricate and test these beautiful machines - from concept to road ready.





DESIGN

Bicycle design is an expression of the purpose. Our purpose is is to design and create bicycles that offer better riding experiences. We don’t design bicycles to win over magazine reviewers or trade show awards. We don’t innovate for innovation’s sake and we don’t rely on gimmicky, proprietary technology to convince you that our bikes are different. Our bikes are purpose built using industry proven principles of composite engineering and aerodynamics, combined with only the best quality materials to deliver beautiful, high-performance yet user-friendly bicycles. Every bike we design is tested in-house, by the people who own the company, to ensure they meet up to our exacting standards. At the end of the day, we are not simply industrial designers making a consumer good. We are passionate riders who are privileged to develop our take on one of  mankind’s greatest achievements - the bicycle - and offer it to riders like you.





R.E.A.L. CARBON FIBER

Call it functional advanced composite technology, call it optimized compaction low void - whatever. We understood that to be taken seriously as a bicycle manufacturer, designing and building awesome bikes, in the shadows of the mega brands - then we needed an acronym to sound legitimate. That’s why we came up with R.E.A.L. or Really Exceptional Authentic Lingo.

Of course, this is a bit tongue in cheek. We don’t need an acronym to explain to you the exceptional level of quality carbon we put into our bikes. We never compromise on raw materials and only source the best materials the industry has to offer - like the venerable Toray T700, or the super strong Mitsubishi Rayon M60. You will never find inferior materials hidden behind confusing acronyms on our framesets to meet a price point or to enhance our margins.

So when you see the R.E.A.L. moniker on your bike, know that for a fact you are riding the best materials on earth.

R.E.A.L adjective re·al \ˈrē(-ə)l\
1 - not fake, false, or artificial
2 - not artificial, fraudulent, or illusory
3 - being precisely what the name implies

MATERIALS
We never compromise on raw materials and only source the best materials for their given purpose. No confusing acronyms or proprietary mumbo-jumbo, we are proud to use the best the industry has to offer from our carbon suppliers like Toray who supply the high-modulus T700 carbon fiber for our Kampionne and Koursa models; and Mitsubishi-Rayon who supply us with the incredibly strong, yet lightweight M40 and M60 for our KÜDÜ. We never offer a “comp” or “sport” model using inferior materials so you will never find lesser materials on our framesets to meet a price point or to enhance our margins. Our most affordable and most expensive bikes are equipped with the same high-modulus carbon fiber frameset. No matter how you end up custom building your bike at the end of the day, your bike is spec'd with the same high-end, high-quality and high-performance chassis. Something nobody else in the industry can say.


TORAY T700
TORAYCA® T700 is a high-modulus carbon fiber, featuring high tensile strength, low weights for an overall well balanced composite. Designed and developed to meet the weight saving demand of for the Boeing 777 aircraft. It is the only carbon fiber that has attained certification from the FAA for the critical flight path components for the Boeing 777. It is often said that T700 is the highest grade of carbon fiber that could be used as the sole material in a complete frameset design due to it’s light weight, strength and durability. It’s our favorite material as it is so versatile and well suited for a range of applications. It can be found on our Kampionne and Koursa models.

TORAY T500
TORAYCA® T500 is a mid-modulus carbon fiber is known for its balanced composite properties, high quality, consistency and reliability. It can be found in the layup schedule along with the T500 on the MonoArc design of our Koursa model. We’ve used it’s natural dampening properties to give the Koursa it’s mile-conquering smoothness.

MITSUBISHI RAYON M60
The M60 line of carbon fiber is a high-modulus textile with enhanced tensile and compressive strength. It was designed specifically for the sporting good industry and can be found, believe it or not, in many of today’s top golf shafts. While it’s found some use in the aerospace and aeronautical industries its insane durability and lightness have helped us make the KÜDÜ Cyclo-Cross bike the course crusher that its.

MITSUBISHI RAYON M40
The M40 line of carbon fiber is a slightly lower modulus version of the M60. It can also be found on our KÜDÜ model helping to guide it over and through the rougher patches of the ‘cross course or trails as it’s known for its compliance.





CONSTRUCTION

Our bicycles are designed alongside our factory engineers to meet our incredibly high standards. We can count on over a century's worth of composite engineering and fabrication experience from our manufacturing partners in the United States, Taiwan, China Japan.


LAYUP SCHEDULE
Not all carbon fiber bikes are created equal. One round tube can offer a totally different ride quality and tensile properties to another tube of the same size and shape. We spend countless hours devising the most suitable layup schedule for our composite bikes. Simply put, we make sure the right carbon is in the right place using a plethora of layup techniques and schedules. Often times, these schedules can vary between frame sizes of the same model - ensuring consistent ride quality and performance across our range.

TUBE-TO-TUBE
Or “BTC” or Bonded Tube Construction can be found on our line of KÜDÜ Cyclo-Cross bikes and is very similar to traditional welded construction. Pre-molded tubes and shapes are set in a jig where they are bonded together in a method where we wrap carbon fiber around the joint, and then fix it with resin epoxy. The joint is then thermoset which creates a true fiber composite bond. The result are joints that achieve exceptional strength compared to other bonding methods. In the case of the KÜDÜ, we utilize the Tube-To-Tube construction to ensure the frame stands up to the most treacherous terrain a ‘cross course or unbeaten path can throw at it.

MONOCOQUE
Monocoque construction differs from Tube-To-Tube construction in that nearly the entire frame is laid up in a custom shaped mold. In the case of our Kampionne and Koursa monocoque models, we use precision formed steel molds along with 3D foam cores and silicone mandrels to form the shape. Unidirectional carbon laminate is applied directly into the mold, where the layup schedule is applied - similarly to how we produce our carbon tubing in the Tube-To-Tube process - but utilizing highly customized and optimized tube shapes. The carbon fiber is then fitted inside of the mold using an inflatable silicon bladder. Once the materials are formed inside the mold, it is thermoset before being mated to any other carbon tubes or shapes needed to complete the frame. With monocoque designs, elongated linear shapes replace tubes and joints which permits the larger structure to handle all of the load applied. In the case of a bicycle, that would be pedal resistance, road feedback and impacts. This means, we can utilize fewer materials to produce a much lighter and stronger frame.





QUALITY CONTROL

Our Quality Control checklist includes a variety of key check points before the frames ever leave our factory doors. These include but are not limited to ensuring that each of the mechanical interface points - such as the bottom bracket shell, headset races, dropouts, brake bosses - are fully functioning and ready to assemble. We also ensure that the finale weight of each frame and fork is within our desired tolerances.

Every bike we design is tested in-house, by the people who own the company, to ensure they meet up to our exacting standards. Each frame is tested to comply with CEN/EN standards. We also employ a host of tests that are not required by the CEN. Stiffness is tested on each and every frame and fork that is released from its mold to ensure that it will meet our design standards. Yes, it’s more expensive. Yes, it’s more time consuming - but it’s part of our commitment to Do What’s Right For Riders, to produce better quality products and to deliver better riding experiences - it’s totally worth it.






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