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High-tech made in Europe - the PAVO IV carbon frame

16.11.2023 |Insights

High-quality carbon fibres, full-monocoque construction and autoclave production in Europe: the PAVO IV defines highest standards in carbon frame manufacturing.

High-end frame production

Our PAVO IV carbon frame sets new standards: while offering sophisticated aerodynamic optimization, with a weight of only 800 grams. This unrivalled fusion of lightweight and aerodynamics is possible due to state-of-the-art development and manufacturing methods.

To be able to produce the PAVO IV carbon frame (which is developed with the aid of flow simulations) at this high level, we combine the best materials with ultra-modern production methods. We use the highest quality carbon fibres, from which an elaborate, hand-made full-monocoque frame is manufactured, using an autoclave process. The frame is built in Europe to ensure maximum quality standards in the manufacturing process.

High-quality carbon fibres

Carbon fibres are the heart of any carbon frame. For the PAVO IV, we make no compromises when selecting materials: to build the frame we primarily use Torayca M40J, an expensive but extremely high-quality high-modulus fibre from the leading Japanese manufacturer Toray. With this fibre, we achieve maximum frame stiffness, low weight and high resistance at the same time.

Full-monocoque construction

To build a carbon frame, many individual fibre panels are placed in a mould by hand, in which they are glued ("laminated") with resins. Carbon frames usually are glued together ("fused") from several parts to save costs - as this allows smaller, significantly cheaper moulds to be used. However, the resulting adhesive joints between the components cause additional weight and reduced strength.

To achieve the extremely low weight with high rigidity at the same time for the PAVO IV, we laminate the entire frame in a single mould. This type of frame is referred to as a "full monocoque frame". This construction method is more complex and more expensive than fusion construction. It is the ideal way though to achieve our high development targets for the PAVO IV: light weight, stability and quality.

In brief: the advantages of the full-monocoque design

The advantages of a full-monocoque frame over conventional monocoque fusion frames are what make the top performance of the PAVO IV possible:

  • lower frame weight
  • higher, consistently controllable stiffness throughout the frame
  • no joints in the entire frame

The autoclave process

Going even one step further in terms of light weight and surface quality, the next production step involves baking the frame in the mould in a pressurized chamber - the so-called "autoclave". This state-of-the-art production method is comparatively cost-intensive. However, it provides a perfect environment for curing the frame, in which temperature, pressure and vacuum can be specifically controlled. The autoclave pressure makes the fibre material extremely compact and prevents possible air inclusions.

Often in the production of carbon frames, the much simpler hot-pressing process is used. It however does not offer the same surface quality and control over the curing cycle. 

The autoclave process not only allows further advantages in terms of weight, but also offers the highest processing quality and therefore the highest level of safety for carbon frames. The frame surface comes out of the mould smooth and of such high quality that the frame is theoretically ready for use without post-processing or painting.

Post processing

After the full-monocoque frames of the PAVO IV have gone through the curing cycle and are removed from the mould, the frames are machined in 5-axis CNC milling to achieve the final touch of perfection.. They are then polished and sanded both manually and by robot. In this way, we achieve a perfect surface that fulfils the highest quality and safety standards.

Production in Europe

To ensure our high quality and safety requirements for the state-of-the-art production methods described above, we have brought the frame production of the PAVO IV back to Europe. The short distances between the frame production site and our assembly facility not only enable a short and secure supply chain, but also particularly close coordination in the development and optimisation of the production process.

Bottom line

In many respects the PAVO IV is a revolutionary model for us and our demanding customers. The fourth generation of our classic racing bike not only combines lightweight and aerodynamics to perfection. It also sets new standards for the highest manufacturing quality of modern, high-performance carbon frames - with a particularly high proportion of value added in Europe.

Christin H.
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