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The complete production process of the TOTAL ECLIPSE
FRAME takes place in Germany. Through close cooperation
with an aerospace and aircraft industry supplier we ensure
a level of quality unknown in the bicycle business so far.
MAXDENSITY CARBON
Carbon fiber parts mainly consist of two components, carbon
fibers embedded in a matrix of resin. The fiber weave is embedded in the
resin and shaped according to the intended use. The structural integrity
is ensured by the weave of carbon fibers. The resin alone would yield
a very brittle material. The higher the amount of fibers, the stiffer
and lighter the part will be. Thus, the goal is to reduce the amount of
resin needed to bond the fibers, in turn increasing the percentage of
valuable fibers.
The MAXDENSITY process is an advanced production procedure enabling
us to increase the amount of fibers to 65% in the frame material. This
high–quality material, which before had only been utilized in the
production of aerospace and aircraft components, is now used for bicycle
frames for the first time. However, MAXDENSITY CARBON requires
the use of expensive special vacuum ovens for the final baking of the
frame to heat the frame according to a specific schedule.
Every TOTAL ECLIPSE FRAME is completely hand-built. |
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| Artist at work: Designer
Franz Waggershausen cutting and shaping the fiber weave.
Only hand layering by experienced craftsmen ensures perfect
quality. |
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| Finite elements analysis: The
direction and dimensions of each carbon fiber mat is calculated
individually through our proprietary computer modeling. |
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Optimized suspension
and dampening
After the initial idea for the TOTAL ECLIPSE FRAME we used
detailed computer modeling to calculate all details of the frame to achieve
the desired stiffness in every direction: Stiff at the bottom bracket
and steerer area, while giving optimal comfort at the seat.
This
unique combination of power transfer and comfort makes
the TOTAL ECLIPSE FRAME the most efficient bicycle
frame available today. Similar characteristics are
not attainable with traditional diamond-shaped designs,
which - thanks to the junction of four tubes at the
seat cluster - are the most unforgiving where you
are most craving for some relief: at the seat! Due
to the nature of their outdated design traditional
frames offer much more stiffness at the seat than
anywhere else. Shouldn’t it be the other way
around?
The TOTAL ECLIPSE FRAME design, on the other hand,
combines high comfort at the seat with ideal stiffness
where you need it – the drivetrain and the steerer.
Contrary to traditional frames, our top tube’s
sole responsibility is to keep the seat in place, nothing
else. Unhindered by other demands we could equip this
part of the frame with the properties needed for optimized
comfort without any negative influence n the rest of
the frame.
The result is a more efficient frame in a truly beautiful
package.
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Cutting of carbon fiber
mats
The carbon fiber is cut with the help of a stencil |
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Putting into the mold
The precut carbon fiber weave is carefully placed in the mold.
To ensure highest efficiency the fibers run over the entire length of
the material.
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Hollow core
Unlike other frames which are shaped around a heavy foam core,
our MAXDENSITY process allows us to use a hollow core. |
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Hardening in the autoclave
Our advanced vacuum oven delivers higher quality parts.
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The beauty arrives
After careful cooling the mold is opened and the result is
checked.
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Hand finishing
Rear section, steerer, seat tube and bottom bracket are hand
finished for perfect results.
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Nothing but clear coat
The frames are painted in clear coat to allow unhindered view
of our perfect frame surface. This lets you admire the beauty of the carbon
weave ride after ride.
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Certifications for highest precision
Our production plant is a certified aerospace manufacturer.
These certifications guarantee highest production quality. Only these
credentials allow the production of components for the extreme demands
of the aerospace industry. We use this expertise for one of the best bicycle
frames on this planet. |
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