TECHNOLOGIES

Certainly, the most high-performance composite material for manufacturing is Carbon Fiber. When traditional raw materials fail to meet the need for extreme lightweight and high strength, many industries have turned to this technology, initially used by NASA.

COMPOSITE INDUSTRIE

The main characteristics of composite materials are:

Superior mechanical properties
Lightness and stiffness
Low density and dimensional stability
Ability to create complex shapes
Resistance to high temperatures and fire resistance
High corrosion resistance

Carbon fiber

-Tensile strength 4900MPa.
-Elastic module 230GPa
-Density 1.8g/CM3.

ARAMID FIBER

-Tensile strength 3200MPa.
-Elastic module 125GPa
-Density 1,44g/CM3.

hONEYCOMB

-Compressive strength 1,86MPa.
-Shear resistance 2,27 MPa
-Density 49,65 Kg/m3.

UNIDIRECTIONAL FIBER

-Tensile strength 4900MPa.
-Elastic module 210GPa
-Density 1,75g/CM3.

UNIDIRECTIONAL FIBER

-Tensile strength 4900MPa.
-Elastic module 210GPa
-Density 1,75g/CM3.

HYBRID FIBER

-Tensile strength 4000MPa.
-Elastic module 125GPa
-Density 1,44g/CM3.

nomex

-Compressive strength 1,9MPa.
-Shear resistance 1,16 MPa
-Density 48 Kg/m3.

GLASS FIBER

-Tensile strength 3400MPa.
-Elastic module 72GPa
-Density 2.54g/CM3.

Zylon

-Tensile strength 5800MPa.
-Elastic module 270GPa
-Density 1,56g/CM3.

Core

-Compressive strength 1,22MPa.
-Shear resistance 1,06MPa
-Density 80 Kg/m3.

production

Production technology and composite materials are constantly evolving, and for Carbonmade, technological innovation represents a priority and corporate philosophy.

AUTOCLAVE PROCESS

This production process can ensure high-quality performance characteristics of both structural and aesthetic components.

The autoclave allows for the polymerization of materials through controlled and uniform temperature and pressure cycles.

It is an extremely versatile technology as it allows for the simultaneous production of objects of both small and large dimensions with complex geometries, all distributed within the autoclave during the same curing cycle. Depending on the type of materials, structures, and internal fillers, a specific ramp is associated to catalyze the internal resin.

STAGES OF THE PRODUCTION PROCESS

Application of release agent
Cutting of pre-preg fabrics and fillers
Lamination on the mold
Application of the vacuum system
Autoclave polymerization cycle
Extraction from the mold
Drilling and final finishing

Application of release agent
Cutting of pre-preg fabrics and fillers
Lamination on the mold
Application of the vacuum system
Autoclave polymerization cycle
Extraction from the mold
Drilling and final finishing

EQUIPMENT

Clean Room 1 – DIM 500 m²
Clean Room 2 – DIM 350 m²
Autoclave 1 - DIM 7 m x 1,5 m (200° – 10 bar)
Autoclave 2 – DIM 4,5 m x 2 m (200° – 8 bar)
Autoclave 3 – DIM 4 m x 1,8 mt (250° – 12 bar)
Cutting plotter 1 – X continuous and Y 1250 mm (cutting thickness max. 25 mm)
Cutting plotter 2 – X continuous and Y 1500 mm (cutting thickness max. 35 mm)
Industrial oven – DIM 2 m x 1,5 m x 1 m
Cold storage 1 – DIM 2 m x 2 m x 2 m
Cold storage 2 – DIM 3,5 m x 2 m x 2 m

Clean Room 1 – DIM 500 m²
Clean Room 2 – DIM 350 m²
Autoclave 1 – DIM 7 m x 1,5 m (200° – 10 bar)
Autoclave 2 – DIM 4,5 m x 2 m (200° – 8 bar)
Autoclave 3 – DIM 4 m x 1,8 mt (250° – 12 bar)
Cutting plotter 1 – X continuous and Y 1250 mm (cutting thickness max. 25 mm)
Cutting plotter 2 – X continuous and Y 1500 mm (cutting thickness max. 35 mm)
Industrial oven – DIM 2 m x 1,5 m x 1 m
Cold storage 1 – DIM 2 m x 2 m x 2 m
Cold storage 2 – DIM 3,5 m x 2 m x 2 m

PATENTS

AIR SADDLE PROJECT

In the specific case of bicycle saddles, we have seen in recent years an evolution aimed at improving the quality of materials and the surface conformation on which the cyclist sits, to offer greater comfort and pedaling efficiency. However, this evolutionary path has kept unchanged the system with which the saddle is attached to the seat post, through two forks, which allow both translation and rotation of the saddle itself, acting as rails.

The innovation of the Air Saddle lies in simplifying this concept. This monocoque construction allows both weight reduction and achieving a sharp, innovative, minimalist design, where functionality and aesthetics converge to the same result.

The Air Saddle represents the pinnacle in terms of design and performance, material quality, and production technology, and it is the current benchmark for sportiness and lightness in the field of racing bike saddles.

This project is covered by several patents for industrial invention and will soon be available in the market for the main leading manufacturers in the sector.