Carbon Frame Building Process Monocoque vs. Tube-to-Tube Construction

Monocoque Construction

The majority of the bicycle industry uses the monocoque fabrication technique to build their carbon frames. Carbon material that has been pre-impregnated with resin is laid up in a precise manner to give the frame strength. Inside, a bladder is inflated to very high pressure to push out any air bubbles in the material and compress the carbon into its final shape. In many monocoque frames, the chain and seat stays are attached after this process is completed.

Tube-to-Tube Construction

Formigli’s tube-to-tube construction is completely different from monocoque. It allows us to take your specific individual body measurements and build a frame that is designed to get the most out of your unique dimensions.

In the tube-to-tube method, each tube is cut to your measurements and then positioned in our alignment machine. The tubes are then bonded with epoxy glue. After the tubes are bonded, carbon fabric is applied to form lugs that join the tubes together. The frame then is further reinforced by wrapping carbon around all the joints.

Next, the tubes are filled with sand (to prevent deformation) and placed in a plastic vacuum bag (proprietary vacuum sealing technique) for the curing process. The sand prevents deformation of the tubing during the heating process and the vacuum creates a space devoid of air.

After the frame is prepped, it is heated to precisely 248°F for one hour and then slowly returned to about 100°F over a period of ten hours. Once removed from the oven, the bag is inflated, the frame is removed and the sand is cleaned out.

The Finishing Process

After the finished frame is cured it goes through a meticulous sanding process to create the aesthetic beauty that sets Formigli apart from other carbon frames, not only as an incredible riding machine, but also as a fine Italian work of art. You might think of it as a Ferrari of carbon frames.

The final stage is the application of a resin like substance that seals the porosity of the carbon and readies the frame for painting.