Carbon fiber is now the most widely used material for building high-end bicycles. All production is done in Italy, as our country is home to some of the best carbon fiber manufacturers. These companies, due to their proven technical and manufacturing skills, count among their clients brands like Ferrari and Ducati.
For each Formigli model, specific tubes are produced according to the quality segment of interest. The first step in frame construction is, without a doubt, the design, which outlines the shape of the object to be achieved, constantly checking its faithful adherence to the original idea through a 3D model.
Next, with the consultation of a carbon fiber technician, the profile and performance of each tube are carefully examined to decide which variant of the material is most appropriate for its use. With this system, after testing tubes of various shapes and combining them with different carbon fiber fabrics, we have managed to achieve high torsional rigidity across the entire range. To configure a frame that is strictly “custom-made”, specific and precise information about the cyclist’s style and physicality is needed to ensure a unique and fully personalized bicycle. However, the verification of the customer’s measurements is crucial to best configure the performance and actual handling of the bike. After the design, the real manual work begins: the tubes are first machined, and then fitted onto the construction jig. Following the pre-assembly of the frame through a sealed bonding process, the “vacuum carbon layering” process begins, a method that allows us to create a much stronger frame compared to other procedures. Finally, the joints are meticulously sanded and hand-finished.
These processes are the essential characteristics of Formigli products, which require particular care and great precision. The tube-by-tube construction process guarantees a perfectly customizable frame and allows the use of any type of carbon fiber, depending on the intended use and the bike’s configuration. Once the work is completed, graphics and colors are developed in collaboration with the client, who can rely on our painting expertise, where each frame is individually followed from start to finish, ensuring that we deliver a unique product to our client.
