The material potential can be utilized to a high degree with regard to force transfer direction and height using two-dimensional surface processing with a corresponding adaptation to the power flows. However, complete utilization of mechanical potential cannot be achieved without a three-dimensional configuration of the materials. ax-lightness components contain many features that can hardly be detected from the outside. For instance, sandwich materials and even supporting webs are used to take parameters such as damage tolerance or stiffness to new dimensions without compromising lightness.

seamless brake surface

The one-piece, seamless brake surface provides a perfectly planar brake surface and completely eliminates brake judder or stutter. This is a real advantage in terms of safety.
For optimum functionality, we recommend using carbon-specific brake linings on our rims.

spoke reinforcement technology
 
Thanks to the stress-optimized reinforced spoke holes laminated and reinforced during production no additional drilling is necessary, making weaknesses in structure a thing of the past. The drawn-out nipple seatings also ensure perfectly aligned nipples. As a result, the rims work without a general limit on spoke tension – we spoke our own wheels with 1300 N!

The production of optimized load-resistant structures is top priority at ax-lightness. With many products and manufacturers, this step separates the wheat from the chaff. At ax-lightness we go even a step further on request and adapt the layups of our frames to the needs of our customers. This is how we can make a frame that is comfortable or even extremely stiff without losing sight of safety – and we're the first in the world to do it!

Autoclave compressed laminates

A laminate isn't a high-performance composite unless the individual layers are optimally joined. Inclusions between the individual layers are simply unacceptable. For complex moulds, this presents a challenge and can only be achieved using autoclaves. The layers are joined under enormous pressure in an autoclave. This is special because the pressure is applied with gases that compress the laminate down to the smallest corner regardless of its shape. This perfectly joins the layers, while simultaneously pressing out entrapped air. This is the only technology that can meet the toughest demands placed on engineering worldwide: the demands from astronautics! It is a completely new approach in the cycling industry.

Pre-formed layup

Fibre materials can only be used safely when they are perfectly aligned. Fibre deformations caused by inaccurate cutting of the prepegs, careless lamination or overstrung fibre strands increase the safety risks in these materials. For this reason we place our individual plies on precisely adapted lamination cores and compress the individual layers between the plies so that we can ensure that each individual fibre retains its exact position and does not warp during the hardening process under the high pressure of the autoclave. This method takes two to three times longer than conventional methods but leads to unmatched technical values!

Released surface quality

Components made of carbon are typically finished with paint. This is always necessary when the surface quality is relatively poor after demoulding. Multiple layers of paint then turn a defective part into a "state-of-the-art-product". When lamination quality (PFL), materials, hardening cycles (ACL) and production site cleanliness are optimal, the result is a pure surface quality. ax-lightness products are always delivered unpainted for exactly this reason. Our special manufacturing technologies guarantee the best surface quality. Our quality is evident at first glance, and also holds up to critical testing: This is why we only apply our ax-lightness decals to the surface without coating them.