Bringing the design phase to life; when we create a prototype we breathe life into the machine that will create charged moments of joy in the rider. A prototype frame is developed based on design specifications and made ready for factory development testing. The production techniques and processes have been carefully refined over a period of many years to ensure superior quality is achieved. But it doesn’t stop here as the design.
and production teams work in synergy continually seeking improvements in techniques and processes. it right. Individual frame drawings are made for every Avanti model and every size of every model. This means unique and exclusive Avanti frames specifically designed for certain performance attributes are made for every bike influenced by the ADT philosophy.

Tube Butting (Aluminium only)

A process where the tube is pulled and/or pushed over a mandrel (former) to create different wall thicknesses along its length. With this method the tube can be made thicker or thinner where required.

Tube Forming (Aluminium only)

This covers a wide range of different techniques that are used to form tubes to various shapes. Tubes can be bent using mandrels and/or can have more unique shapes with the use of pressing against a specially shaped tool. The picture (right) shows a tube being clamped in a press with the end being formed by a mandrel (1) that enters from the end.

Hydroforming and Super Plastic Forming (SPF)/Air forming (Aluminium only)

The basic or preformed tube is placed into a specially shaped metal tool. Either oil (hydroforming) or air (SPF) is introduced to the inside of the tube at very high pressure. The tube deforms out against the tool forming it to shape. Complex tube shapes are possible with these methods.

Forging (Aluminium only)

With this method a solid piece of aluminium is placed inside a tool that is a negative of the required shape. The tool is closed on the metal and squeezes it to the correct shape. This creates

accurate detailed shapes and due to the compression and uniformity of the metal the parts are stronger and more fatigue resistant.

Hydroforming and Super Plastic Forming (SPF)/Air forming (Aluminium only)

The basic or preformed tube is placed into a specially shaped metal tool. Either oil (hydroforming) or air (SPF) is introduced to the inside of the tube at very high pressure. The tube deforms out against the tool forming it to shape. Complex tube shapes are possible with these methods.

Aluminium Alloy Tube - Welding

TIG (Tungsten inert gas) welding is used on our aluminium frames. Smooth welding techniques are sometimes used for aesthetics and fatigue strength reasons. Although on some frames certain components may be automatically welded using robotic welders most of the frame tube joins are usually welded manually by hand. The picture on the left shows a robotic welding process, whilst the

the left shows a robotic welding process, whilst the picture on the right shows the more traditional alloy manual welding operation. Various jigs and fixtures are used to hold the frame to the correct geometry when welding.

Modular Monocoque (Carbon only)

This is a process in which the front triangle, seat stays, and chain stays are moulded as individual sections. This allows us to completely optimize each frame section toward a specific requirement; be it Torsional stiffness for the front triangle, or vertical compliance in the seat stays. Each of these frame sections is made of multiple layers of carbon. The number of layers is not constant along the entire part: in areas where the load on the frame is high, more layers are used; and in low stress areas, fewer layers are used to save weight. After these individual sections are created, they are fused together into a seamless Monocoque (one-piece) structure.

EPS - ETHYL Poly Styrene (Carbon only)

In order to have more stable and consistent production we have introduced EPS into a number of our Team bikes. EPS is a new-patented innovation that will enable products to be made with stable dimensions, and smoother inner layers. This technology is called “wrinkle free system”. Uses internal mould in the production process.

HTR - High Toughness Resin (Carbon only)

Another new development within our Carbon Fibre manufacturing is HTR. This is an exclusive material that has been developed with one of our most advanced carbon manufacturers. This technology has been designed to meet the demands for better performing, lighter and stiffer frames. The utilization of this technology in our Team frames will give the following advancements:

  • Higher impact resistance (approx. 20%)
  • Improved test performance over current carbon fibre resin:
    • Regular Resin = 80kg/cm2
    • HTR Resin = 98kg/cm2

Next: Stage 5 - TEST

Rigorous testing procedures begin with factory lab testing. All bikes are tested with exhaustive tests such as the 100,000 cycles dynamic load test.

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