Two hours south of Salt Lake Metropolis lies the small city of Gunnison, Utah. House to huge swaths of farmland and cattle pasture, Gunnison can be the headquarters of CSS Composites, the dad or mum firm of Forge + Bond, which designs and manufactures thermoplastic carbon fiber wheelsets.
CSS shares its campus with ACT Aerospace, a composites facility that has been manufacturing aerospace elements since 1985. The experience, and the numerous funding behind CSS, which makes use of novel thermoplastic composite methods instead of extra generally used thermoset (epoxy-based) manufacturing, comes from the lengthy and profitable historical past and wealth of expertise of ACT.
The campus contains a number of giant buildings and a formidable photo voltaic array; conventional composites manufacturing is very power intensive. Uncooked supplies have to be saved at very low temperatures prior to make use of in order that they don’t degrade, and the method of turning these supplies into completed, usable elements takes immense quantities of warmth and stress, usually by way of giant, submarine-esque autoclaves.
In distinction, the method CSS makes use of to make Forge + Bond rims requires far much less power. It’s additionally surprisingly clear, environment friendly and astonishingly quick: a wheel can go from uncooked supplies to being ridden in lower than two hours!
Biking Weekly visited the CSS manufacturing unit to see this course of from begin to end.
Contained in the CSS Manufacturing facility
(Picture credit score: Anne-Marije Rook)
When CSS first launched its wheels, the corporate was hesitant to share the precise sequencing and methods being utilized to supply them. Since then, nevertheless, it has grow to be extra open in regards to the course of. The rationale for this, in accordance with Brett Stahl, VP of Model and Advertising and marketing at Forge + Bond, is that because the inventors of this course of, the folks throughout the firm know exactly what number of assets have been required to develop the equipment and methods wanted to fabricate these merchandise. In consequence, they understand how troublesome it might be to duplicate.
The primary cease on the tour was visiting the ACT Aerospace manufacturing services. We have been ushered by means of a number of doorways into loud industrial areas busy with folks reducing uncooked materials, laying up carbon fiber sheets by hand and doing the messy end work that’s vital for these giant scale thermoset composite items. ACT producers elements for satellites, specialised aerospace purposes, and extra. We walked previous large autoclaves, a formidable machine store, and the hulking carapaces of helicopter and different plane elements stacked as much as the ceiling. ACT and affiliated companies below the identical roof make use of a number of hundred folks from Gunnison and the encompassing space, and it’s clear these individuals are superb at what they do.
Surprisingly clear, environment friendly and astonishingly quick: a CSS-made wheel can go from uncooked supplies to being ridden in lower than two hours!
Subsequent we visited CSS’s wheel constructing facility. As an alternative of large freezers stocked with completely different mixtures of pre-impregnated resins, there have been just a few pallets of boxed fiber spools sitting on the ground, at room temperature. The uncooked materials, manufactured by Toray, involves CSS in a number of polymer mixes, that are utilized in numerous methods to optimize every wheel design. It was nonetheless loud right here, however as an alternative of dozens of individuals laborious at work, there was only one: a single technician runs the primary two machines that start the method of creating FusionFiber rims.
The distinction between the 2 composites methods couldn’t be extra stark: constructing wheels utilizing thermoplastics means no fridge, no autoclave, and as an alternative of many palms, just a few (giant, noisy, imposing) robots. Regardless of all the work that went into creating these methods, the method is definitely digestible.
The Course of
Forge + Bond wheels within the making
(Picture credit score: Tyler Boucher)
First, unidirectional tape is wound onto particular spools, very similar to winding thread onto a bobbin. It’s then loaded onto a Dieffenbacher machine referred to as the Fiberforge, which CSS co-developed with the German equipment manufacturing firm (value: many hundreds of thousands of {dollars}).
The Fiberforge cuts the tape into quick sections at robotically exact lengths and angles, then ultrasonically tacks them collectively within the form of a wheel. Every mannequin that CSS manufactures (there are a number of completely different Forge + Bond rim shapes, in addition to rims for Chris King, Trek and others) makes use of completely different mixtures of polymer-infused tape relying on the specified driving traits. 4 to 6 minutes later, a flat, multi-piece carbon wreath is spit out on a tray, with out the identical violence, however in the same strategy to a money register drawer opening. The velocity the machine is tuned to is decided by the tape getting used and the stress of the spool.
(Picture credit score: Tyler Boucher)
The technician then strikes every flat multi-piece wreath over to the consolidation machine, referred to as the Fibercon, one other Dieffenbacher creation (and once more costing many hundreds of thousands of {dollars}), which vacuum compresses the person sections of tape into one single piece. The Fibercon is designed to carry two tack-welded pre-rims at a time, aspect by aspect, and strikes them round for every stage of the method at precisely the proper time with out human enter. It first heats them up utilizing infrared, then slides them over to be water-cooled, at which level the 2 items (half of a rim, every) emerge, heat to the contact. This complete course of solely takes a couple of minutes.
(Picture credit score: Tyler Boucher)
Thermoset composites, because the identify implies, arrange as soon as after which can’t be reheated and remolded. The FusionFiber system, in distinction, makes use of the repeated heating and cooling approach as the idea of its manufacturing approach. This is among the some ways the 2 processes differ. The implications of this make the Forge + Bond’s rims a lot simpler to fabricate: being heated and cooled over and over with out altering chemical make-up means issues might be batched. If the rim items want to take a seat for some time, it’s not an issue; every step of the method can cease and begin as wanted and workflow might be adjusted to swimsuit particular wants.
The subsequent step is shifting to one more Dieffenbacher machine for urgent. That is how the person items, which hitherto are fully flat, get molded into the form of a bicycle rim. Every wreath-shaped piece is mounted separately right into a suspended rack, held in place by tabs made expressly for this goal. It first strikes into an infrared heating chamber, then is dropped onto an aluminum mildew and pressed into the form of a rim sidewall. This takes only some minutes, and items come out clean, with a completed floor requiring no extra therapies.
(Picture credit score: Tyler Boucher)
Subsequent, the items are taken to a water jet that trims off extra materials. That is accomplished in a matter of seconds. Trimmings come off as one piece outers and inners, and these are saved to be repurposed into different issues (extra on that later).
The ultimate molding step of the method takes the 2 fashioned sidewalls and locations them into an aluminum mildew together with a channel piece (this the rim mattress, which is manufactured individually utilizing the identical methods) with a latex bladder inside all three items. This step requires essentially the most people; three completely different technicians work collectively to effectively assemble and disassemble molds and insert the carbon items and latex bladder.
Technicians work collectively to insert a latex bladder into the mildew.
(Picture credit score: Tyler Boucher)
As soon as the mildew is bolted collectively it slides right into a Wabash vacuum press, the place the mildew is subjected to important warmth and stress so as to bond the rim items collectively right into a accomplished product. It stays within the press for about six minutes. When the finished rim comes out of the mildew, it will get its latex bladder eliminated and is then cleaned of extra nylon/polymer whereas the perimeters are given a lightweight sanding. It will get inspected after this stage, however is actually finished. The tiny slivers of extra polymer which can be scraped off the perimeters of the rim are the one tangible waste all through your complete course of.
(Picture credit score: Tyler Boucher)
After this step, rims are able to be made into wheels. One more machine is liable for spoke gap drilling, adopted by a lacing machine, at which level the finished wheel will get hand-trued, stickered, and has rim-tape put in. The finished wheel is now prepared for tires to be mounted.
Ultimate step: go for a journey.
Curious in regards to the journey high quality? So have been we! Try our overview of the Forge + Bond GR45 gravel wheels and the CSS-made Chris King GRD23 R45D wheels.
What in regards to the scraps and leftover materials?
(Picture credit score: Tyler Boucher)
One of many promoting factors of thermoplastics is that for the reason that materials doesn’t get altered by means of repeated heating and cooling cycles, damaged or additional items might be floor up and reused. Actually, Toray sells uncooked materials, whether or not in tape type or chipped, for a similar retail worth. For this particular course of, these floor up bits can’t be remade into rims—that requires longer sections of fabric, however all method of different merchandise are doable, from bikes elements like pedals and stems to saddles for equestrian use, ATV purposes, tractor elements, hydrofoil parts, physique armor, and so forth. The record is countless. CSS is quickly connecting with companions to develop these items.
That is the important thing to CSS’s final mission. Sure, the corporate has developed an extremely environmentally pleasant manufacturing course of, nevertheless it’s additionally one which has the potential to make excessive worth elements, then reuse and promote that very same actual materials over and over. It’s only a matter of scale—as soon as the uncooked materials is being utilized in ample portions, it is going to be more and more cheap to perpetuate the cycle. Realistically, the bike business makes up a reasonably small a part of the general pie in the case of manufacturing merchandise.
Probably the greatest elements of the job, says Stahl, is coming in to work every day and asking “what can we make at the moment?” The choices are primarily limitless.
Tire Levers?
Forge + Bond’s carbon tire lever
(Picture credit score: Tyler Boucher)
The primary product Forge + Bond launched with chipped thermoplastic materials was a tire lever, retailing for $50 (a set can be included with every wheelset the corporate sells). This tough-to-stomach worth precipitated some web backlash, although Stahl says the levers promote surprisingly properly.
The purpose, nevertheless, isn’t the levers: they’re only a proof of idea (although a really extremely engineered proof of idea). Taking waste, offcuts, and busted up elements and turning them into new gadgets is the true purpose right here, and creating the levers demonstrates how it may be finished. Different bike merchandise, like pedal our bodies, stems, saddle rails, crank arms and the like could also be obtainable sooner or later.
Individuals could criticize the touted recyclability advantages of thermoplastics as greenwashing, however the course of is already below manner. And at scale, it may actually shake issues up.
We have been in a position to see the lever making course of as a part of my tour. A small portion of chipped materials first will get weighed out, then added by hand right into a small mildew. The mildew then goes into one of many identical Wabash presses used for the wheel mildew the place it sits for a couple of minutes to come back as much as temperature, then will get compressed down earlier than being moved to a different press for cooling. The lever is then faraway from the mildew however must have the tough edges trimmed off earlier than use. Apparently it’s frequent for Forge + Bond at hand out these levers and tradeshows and bike outlets and supply folks the chance to attempt to break them: up to now nobody has succeeded.
The chipping course of is kind of as easy as turning bushes into mulch; materials goes right into a hopper, will get floor up and spit out in exactly the identical manner, with out clouds of poisonous mud or something. Chipped materials sits in bins and rubbish cans all through the power, able to be made into new issues.
Arguably, what CSS is doing when turning rims into different issues is downcycling, not recycling. But it surely’s not theoretical, the corporate is actively doing this. Individuals could criticize the touted recyclability advantages of thermoplastics as greenwashing, however the course of is already below manner. And at scale, it may actually shake issues up.
Constructing wheels for different manufacturers
CSS additionally makes rims for Chris King, Trek and others.
(Picture credit score: Tyler Boucher)
We requested why CSS had launched Forge + Bond whereas concurrently making rims for different manufacturers, which appears as if it might put CSS in direct competitors with its manufacturing prospects.
Stahl defined that after initially creating the method and manufacturing rims for others, CSS needed the liberty to design rims with out outdoors affect. Forge + Bond gives a way to push the envelope on the applied sciences getting used, and because the specialists, put to make use of the issues it has realized to make the easiest product obtainable. Although the edges Trek and Chris King supply are just like Forge + Bond’s choices, every rim has its personal mildew and personal recipe of carbon sheets with completely different polymer/nylon sorts. They might be comparable, however each is designed collectively to the specs of every model.
Thermoset vs. Thermoplastic
(Picture credit score: Tyler Boucher)
Regardless of benefits when it comes to power value, labor value, waste produced and diminished toxicity, thermoplastics do have drawbacks. By way of pure mechanical efficiency (power to weight), thermoplastics can not match excessive efficiency thermoset composites. For this reason we’re not prone to see many bicycle frames made with these methods.
Thermoset frames, particularly within the present period dominated by aerodynamics, will proceed to rule the roost. For the time being, there is no such thing as a higher materials for constructing racing bicycles than epoxy-based thermoset composites. By way of different purposes, thermoset supplies may also stand up to a lot larger temperatures, making them a greater choice for something that will get extremely popular (or very chilly) i.e. aerospace makes use of.
However bicycle rims are a spot the place mechanical efficiency isn’t based mostly solely on power to weight. Damping, particularly for off-road driving, is rather more vital. As is fatigue resistance over time and the way it’s that the supplies fail. Due to the inherent give within the polymers that maintain the fibers collectively, thermoplastic wheels do a lot better over repeated affect and may typically stay rideable even after cracking—making it that rather more seemingly you may make it to the end line, or at the least again to your entrance door.
