Fezzari Monoform™

Fezzari Monoform™ frame technology uses a new process to make carbon frames out of a single mold. The Monoform process eliminates the need for multiple pieces to be bonded together into a single bicycle frame. Each bicycle frame comes out of a single mold. Since the entire frame comes out of one mold, there are no bonded joints. Without bonded joints, the frame can be made lighter and stronger. Also, without a joint cutting the fibers in the chain stays and seat stays short, we can tune the ride characteristics of the frame better.

Most bicycles are constructed using a Monocoque frame process. Monocoque frames have a mold for the front triangle and a separate mold for the rear triangle. The separate pieces of the frame are then bonded together. These bonded joints create weak spots in the frame that are more prone to failure, curing issues, and misalignment. The Monocoque process includes alignment checks, machining, post machining alignment checks, and more. With the Monoform process, we eliminate many of these steps. When the whole frame comes from a single mold, we don’t have to worry about alignment checks or machining. With less steps and a single mold curing process, the frame can be made more precisely and consistently.

Weight – Traditionally, bicycle chain stays and seat stays are machined and bonded to the main triangle in a tongue and groove style junction that essentially acts as a splint. With the Monoform process, there is no need for additional fiber typically required in the chain stay and seat stay areas. Combined with our EPS carbon layup procedures, we are able to save up to 150 grams per frame with MonoForm vs traditional monocoque forming techniques.

Better Ride & Feel – Since there is no splint-style bonding joint, we are able to tune the chain stays and seat stay through the entire length of the frame. This gives a more laterally stiff chain stay for better power transfer, and a more vertically compliant seat stay for a softer and more comfortable ride on rough roads.

Strength & Durability – MonoForm technology allows us to use longer fiber strands because there are no junctions in the seat stay or chain stay compared to other frame manufacturing techniques on the market today. Longer fibers without junctions or bonded sections are stronger and offer better durability. Fezzari MonoForm carbon fiber road frames are tested to cross-country mountain bike testing standards. Because of this strength and durability, all MonoForm carbon frames feature a lifetime warranty.

More consistent production – MonoForm technology allows us to eliminate machining, bonding, and curing that is typical in traditional carbon fiber construction. We are able to better control the overall manufacturing process for the most consistent layup, molding, and frame alignment over the thousands of frames produced. This means better consistency, reduced costs, and lower risk of manufacturing defects.

Carbon has become the high-end go-to material for bike building. It's lighter than aluminum or other materials and can be adapted to be either flexible or stiff. Carbon construction technology has advanced rapidly in the last few years. Fezzari uses the latest technologies, along with our own proprietary technologies to build our bikes. Plus, we back our carbon with the best warranty in the business.

 

 

CleanCast™ Carbon

Cut open any standard carbon frame and rub your fingers along the inside of the frame. You’ll find a rough surface, full of ridges, excess bonding in the joints, and wasted material. On the other hand, cut open a Fezzari CleanCast™ carbon frame and you’ll notice how smooth it is. There are no joints. No creases. No excess resin. No wasted material.

What’s the benefit? Fezzari CleanCast™ carbon is:

  1. Stronger - we test our frames at 130% of ISO standards and guarantee them with a lifetime warranty
  2. Lighter - weight savings of 20%
  3. Performs better - reduced joints means more performance consistency

How do we do this? Through our new proprietary manufacturing methods. Without getting too detailed, here’s what we do:

  1. Internal and external molds - rather than use the standard one mold where a raw carbon form is placed inside and inflated with a bladder from the inside, we use an internal mold that gives us much more precision and less waste.
  2. Longer fibers - the internal mold allows us to use longer fibers in the assembly process. Longer fibers mean stronger frames.
  3. No joints - most frames have joints in them with overlapping carbon. Those joints become weak spots in most frames.

 

Stiffness and Strength (Modulus)

We use carbon fiber on frames, seat posts, forks, and other components. Carbon fiber is very light and can be made stiff or flexible. The term commonly used to describe stiffness is "modulus." We are often asked what modulus we use. On any given frame, we use all types of moduli - from low modulus to high modulus. Low modulus carbon fiber will absorb impacts better (think of a rubber band), and high modulus is more rigid and strong and can better resist flexing (think of a pencil). Both have their benefits at specific locations in the frame. For example, we use lower modulus carbon fiber in seat stays to make the ride softer, and higher modulus carbon fiber in the downtube to make the power transfer more efficient. We use the highest grades of carbon in the bicycle industry.

Unidirectional Carbon Layup Tech

Unidirectional carbon fiber is one of the newest carbon layup methods we use. For each layer of carbon we lay all fibers within the layer in the same direction for decreased weight and improved performance, and then lay the layers on top of each other in slightly different directions for increased strength.

Tube Shaping

We use a variety of shaping techniques and forms on each of our carbon bikes. Tube shaping is simple engineering. Certain shapes respond better to different forces. From diamond to circular shaping, triangular to oval, all have their specific benefits in creating stiff areas on the bike and also more flexible and compliant areas. All come together with the combination of the different carbon moduli to create a comfortable, yet responsive ride.

Less Waste and Lighter Frames through Better Technology

In traditional carbon layup processes, sheets of carbon are wrapped around an air bladder that has some type of object inside the bladder to keep the form, think of a paper mache project. Then after all the carbon is wrapped around the bladder, the object holding the shape is removed and the bladder and carbon fiber are placed in a mold. The bladder is inflated and baked. The problem in this process is that there is a lot of waste.  The carbon wrapping has to be loose enough to pull the object out of the bladder before the curing process. This loose wrapping can cause overlapping carbon fiber that can weaken the frame or cause unnecessary weight, and creates air pocket voids causing potential frame failure.

We have improved on these traditional techniques by using CAD-created spot specific cut carbon fiber, collapsable mandrills, and higher-quality raw materials.

  • CAD-Created Spot Specific Cut Carbon Fiber (TM) - reduces waste and overlap while making the frame stronger.
  • Collapsible mandrills - used for the objects that are removed from inside the bladder. They come apart like a puzzle, allowing us to wrap the carbon tighter, reducing weight and increasing strength. These mandrills are built on 3D printing machines.
  • Better raw materials - by using better resins and carbon, we reduce the need to use excess materials, resulting in reduced weight and increased strength.

All this leads to a stronger, lighter, and better riding bike.

 

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