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

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

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.