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Many factors influence the making of a great frame,
fork, or component. Design details, construction methods,
and materials are the primary three.
Carbon Fiber is an engineers dream come true: A material
that is lighter than aluminum and is pound for pound
stronger than steel. It can be molded into complex shapes
and sizes, as well as having the ability to be "laid-up"
with more material where you need it, and less where
you don’t. By utilizing this material, we are able
to take our wall specifications and tube shapes to the
next level. Some of these details include oversized
diameters, unique shapes, and exaggerated tapers. Every
frame implements size-specific details. For example:
the tube diameters of a 50cm frame are noticeably smaller
than the tubes on a 60cm frame; even radii and tube
transitions change to support areas of the frame differently.
All of this adds up to a frame that is stiff and responsive,
yet has excellent damping characteristics and vibration
control, specific to the needs of a given size rider.
All Felt carbon frames are created using our Modular
Monocoque Method - the second major factor contributing
to a frame’s performance. This is a process in
which the front triangle, seat stays, and chainstays
are molded as individual sections. This allows us to
completely optimize each frame section toward a specific
requirement; be it torsional stiffness for the front
triangle, or vertical compliance in the seat stays.
Each of these frame sections is made of multiple layers
of carbon. The number of layers is not constant along
the entire part: in areas where the load on the frame
is high, more layers are used; and in low stress areas,
fewer layers are used to save weight. After these individual
sections are created, they are fused together into a
seamless monocoque (one-piece) structure. Since carbon
fibers work best in tension, when assembling the carbon
parts we carefully position the unidirectional carbon
cloth so that the fibers are oriented in the direction
of greatest stress. Unidirectional carbon fiber has
the highest tensile strength, and is used for the structure
of the frame. The Modular Monocoque construction method
is superior to other processes due to the unified design
which ensures perfect alignment, no excess material,
no need for putty or filler in the finishing process,
and no stress concentration; all while delivering minimal
weight, amazing responsiveness, and incredible overall
strength.
All carbon fiber material is not created equal. Simply
looking at the properties of a single material is no
way to judge a frame’s quality. The carbon weave,
or outer appearance, which most people recognize is
typically used only for the final outermost layer, which
is visible through the clear coat. Although this lends
some structural integrity to the frame, it is primarily
cosmetic. So a 2K, 3K, or 12K weave designation does
not necessarily determine a frame’s quality.
 Carbon
Fiber can be ranked in two ways: one being the Modulus,
which dictates the fiber’s relative stiffness;
and the other being Tensile Strength, or how strong
or tough the material is. Building a frame of just the
highest modulus material would be a disaster, as the
ride quality would suffer from being too stiff, as well
as the overall strength being compromised. The key is
to blend different materials with unique properties,
placing them in specifically targeted areas of the frame.
In doing so, we can tailor our frames to possess just
the right combination of stiffness, strength, and compliance
while achieving a desired weight.
All of Felt’s carbon frames use only the highest
quality, premium name brand carbon materials, and it
is how we blend these different types of material which
is the third major factor in optimizing our frames.
Here is a look at the three different carbon materials
and blends Felt employs throughout our bicycle lineup:
*High Modulus : The
carbon fiber in our High-Modulus frame material is a
700ksi fiber blend, and has a tensile strength 7.9 times
greater than 3/2.5 Titanium, and stiffness 3.34 times
greater than 6061 Aluminum.
*Ultra-High Modulus : The carbon fiber used in
our Ultra-High Modulus frame material are 800ksi and
700ksi fibers and are 27% stiffer than material used
in our High Modulus frames. Ultra-High Modulus material
has a lower capacity for retaining resin, which results
in a frame roughly 20% lighter, yet with virtually identical
stiffness and strength.
*Ultra Hybrid Carbon (UHC) : For frames utilizing
our Ultra Hybrid Carbon, we source materials from several
of the world’s leading carbon fiber manufacturers.
We select the optimal blend of three different fiber
types including fibers with tensile moduli as high as
588GPa and strategically locate them based on their
unique attributes; using the toughest carbon fiber in
a given area and the stiffest carbon fiber in another,
delivering a chassis with unmatched compliance, lightweight,
strength, performance and handling.
When it comes to our carbon fiber manufacturing methodology,
it goes without saying that an incredible amount of
design, testing, experience, and cost goes into the
development of each Felt frames and component. The result
is a frame free of compromise and full of performance;
providing you with the ultimate ride, and the ultimate
advantage.
Protective 3K weave laid into a DA mold. |
Fatigue testing of F Series carbon frame. |
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Bikes & Frames