/
Use Case • Sport
High Performance Bike Frame
Reinforced framework for high-level requirements.
/
Understanding The Challenge
Context & Problem
Why Legacy Solutions Are No Longer Enough.
The Context
High performance bicycle frames face increased stiffness requirements while minimizing weight for competitive cycling environments. Teams need the highest level of mechanical performance.
- Competitive cycling demands extreme race conditions
- Unique specifications for professional teams
- Balance between weight and structural integrity
Current Limitations
- Mechanical fatigue: Aluminum or steel frames undergo progressive degradation under repeated stress.
- Vibration: Transmission of shocks to the rider, reducing comfort and efficiency.
- Weight/stiffness compromise: Difficult to optimize lightness and strength simultaneously with traditional materials.
- Multiple Connections: Structural Weaknesses and Additional Weight
Reduced Mass
Total frame weight< 900g for a size M frame (54 cm).
Geometric Tolerances
Dimensional accuracy ± 0.5mm on critical attachment points.
Minimal stiffness
Modulus of elasticity≥ 150 GPa for optimal power transfer
/
Pushing the Boundaries
Technical Requirements
Customer and market specifications
Fatigue Resistance
Life> 10⁶ load cycles without structural degradation.
Functional Integration
Integrated cable ducts, accessory mounts.
Safety Standards
ISO 4210 and EN 14781 compliance for racing frames.
/
Innovation
Our Technology Solution
An innovative approach combining optimization and refined manufacturing.
Reinforcement Fibers
Carbon Fiber
Standard modulus (240-270 GPa), High strength (>4000 MPa), Excellent stiffness-to-weight.
Fiberglass
E-Glass and S-Glass variants, Good impact resistance, Cost-effective option.
Aramid Fiber (Kevlar)
Exceptional impact resistance, High tensile strength, Low density.
Thermoplastic Matrices
PEEK (Polyether ether ketone)
340-380°C
High temperature resistance, Excellent chemical resistance, Superior mechanical properties
PEKK (Polyetherketoneketone)
300-360°C
High temperature performance, Good processability, Aerospace grade
PPS (Polyphenylene Sulfide)
280-320°C
Chemical resistance, Dimensional stability, Cost-effective high-temp option
Modules and Temperature of Use
Composite
PEEK Composites
PEEK Composites
PPS Composites
PA66 glass
Process Temperature
340-380°C
300-360°C
280-320°C
260-290°C
Max Use Temperature
260°C
250°C
200°C
120°C
Applications
Aerospace, Medical
Aerospace, Defense
Automotive, Industrial
Automotive, Consumer
/
Effortless Performance
Technical Capabilities
Performance of our manufacturing system.
Optimized geometry
Smart proprietary simulation model to determine the structural distribution within material. Maximum stiffness in high-stress zones.
- 15% weight reduction
- 24% torsional stiffness improvement
Specific Fiber Orientation
Fine-tuned orientation of carbon fibers according to stress load data. Fibers aligned to withstand traction, compression and rotational forces.
- 30% increase in specific stiffness
Localized Reinforcement
Selective reinforcement in transitions and junctions with supplemental glass fiber mesh ensuring cohesive carbon interconnecting patterns.
- No delamination after 1,000,000 cycles
Material Selection
High strength UD-HM carbon fiber for maximum rigidity. T300 for cushioning, E-Glass transition layers, and aramid at mid-sections.
- Optimal fiber placement at critical sections
Functional Integration
Cable routing optimization within 3D structure with no tolerance barriers. Compatible with flat-mount disc brakes and electronic shifting.
- Shimano Di2 and SRAM AXS ready
/
Effortless Performance
Technical Capabilities
Performance of our manufacturing system.
+52%
Rigidity
In resistant forces at the same weight
-38%
Mass
Less weight with same performance
±0.3mm
Tolerance
Constant production precision
Detailed Performance
Modulus of elasticity
GPa 140 / 150
Tg Temperature
Tg > 130 °C
Vibration Absorption
Up to 25% reduction
Standards Compliance
ISO 4210-6, EN 14764
Ready to Optimize Your Frames?
Our engineers are at your disposal to analyze your needs and develop
a tailor-made solution.
- contact@3dimpregnation.com
- +33 1 23 45 67 89
Free feasibility study • Rapid prototyping • Dedicated technical support