The new thermoplastic carbon fiber frame
from K2 Bike is a manufacturing masterpiece. We use a patented process
to create the only suspension frame in the industry with molded thermoplastic
halves that are bonded to a "backbone" of the same material. Made in the
USA on Vashon Island in the heart of the Puget Sound, our new frame is
molded from meticulously laid-up, super-tough thermoplastic carbon fiber
sheets, a first in the industry.
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The thermoplastic carbon fiber shells are laid up
in mirror image steel molds that are carved from solid steel billet to
exacting tolerances. Varying wall thicknesses in the shells are obtained
from precisely cut sheets of the same material laid into the molds. The
shells are then pressed between two steel halves at 500 degrees F under
10,000 pounds of pressure!
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After the shells are molded, the inner "backbone"
is formed in the same process from scrap material left over from the shells.
Very environmentally friendly! The main purpose of the backbone is to provide
a solid bonding surface between the shells. Bonding the frame together
is much more durable with a backbone of the same material.
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The frame shells, backbone and inserts are prepared
for bonding. The pieces are set up in a jig that perfectly aligns all of
the parts, and the bonding agent is applied by a computer-controlled injector.
All inserts are anodized to prevent any galvanic corrosion between the
different materials. The bonding agent cures and ties together all parts
of the frame.
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The bonded assembly is placed into another jig and
the remaining material, the "flash" is cut off by another computer-controlled
machine. The cable stops and rivets are attached to the frame, and every
frame is checked for alignment on a perfectly level, steel alignment table.
The frames are quality checked one last time for cosmetics and polished
to a beautiful shine!
Compared to the 857 (alum) frame, the new K2
carbon frame is: - Over 50% stronger. - About 50% stiffer. - About 10%
lighter (2.85 vs 3.1lbs).
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