When Ben Farver from Argonaut Cycles decided he was going to make the switch from building custom steel bikes to custom, made in the USA carbon fiber frames, he needed to find some local experts. The team at Innovative Composite Engineering, or ICE, were located just over the river in White Salmon, Washington state. Their expertise lies in everything from SUP poles to products for the aerospace industry. A few phone calls later and they began to meet to discuss a new, proprietary system for manufacturing custom carbon fiber bicycle frames.
ICE and Ben began to collaborate. They both were motivated to develop the frame using the best and most advanced molding technology, and to bring something new to the industry. They both pushed each other to do this without compromise or cutting corners, deciding on a few key points: There would be no vacuum forming, no tube to tube carbon lug bonding and no real hand finishing needed. The process would be streamlined, efficient and most importantly, customizable. While I can’t show you the juicy details, which I can assure you are juicy, I can show you snippets of the Argonaut Cycles process.
It begins with a roll of carbon, which is then cut out based on digital CAD templates on a large cutting bed. Each piece is based on the individual parts’ dimensions. From there, the carbon is inserted into aluminum molds, around a bladder where the resin layup occurs. Then, these aluminum molds are heated, allowing the resin to cure. This is repeated until all the parts are finished. When it’s all said and done, the frame is ready for assemblage.
Shot at ICE, these photos lay out the process used in manufacturing a 100% made in the USA carbon bicycle frame, like my Argonaut Cycles road.
EDIT: see a reply from Argonaut below that answers many questions everyone seems to have…