Design

Our frame design takes advantage of the monocoque structure, which we construct according to parameters defined by advanced engineering and technology. To achieve this, we adopted CATIA as our Computer-Aided Design (CAD) program, which is more commonly used in the automotive industry, given its demand for more complex and structurally sound carbon fiber shapes.

By designing a bike with the sophisticated tools typically afforded to aerospace and automotive, we are free to focus more on the performance characteristics and performance features of our frame design.

Simulation

We use two programs for simulation testing: Femap with NX Nastran to conduct finite element (FE) analyses, and Laminate Tools to define carbon fiber layups. We run a wide range of checks in Femap with NX Nastran, such as comparing tube cross sections to see which one yields the best frame stiffness. In order to conduct a structural analysis based on the carbon fiber layup, we define a layup in Laminate Tools and import that data into our FE analysis. The analysis would identify for example, which bottom bracket layup is the stiffest, or which seatstay layup would give the most comfort to the rider.

Production

Our production process is at the core of EXEPT it’s what sets us apart from other custom builders. We invented and patented a process that allows us to create a custom monocoque frame through a set of variable molds. Thanks to this variability we can adjust the geometry of your ride to fit you precisely. First we measure and trim carbon fiber tubes according to data gathered during bike fitting. Next we connect the frame inside patented molds to produce a monocoque structure.

This way we can both rely on the performance characteristics of monocoque in a sophisticated performance frame design, and offer our customers the possibility to shape their frame according to their geometry and riding style.

Testing

We rely on rigorous industry benchmark testing for our custom rides. The baseline for our lab testing is the International Organization for Standardization (ISO) protocol, to which we’ve added an extra safety margin. Performance testing is done on the road by our test pilots and in collaboration with the famous Zedler Institute in Germany.

Thorough testing procedures are topped off by an established, in-house real-life protocol, which — among other checks — tests the frame’s finish its resistance to ultraviolet radiation and abrasion, or how the frame reacts if the seat clamp is over-tightened. We benchmark our frames in terms of safety and performance against only the best of our rivals in the category of performance carbon fiber frames. Once our frames have been tested during production, we don’t stop there.