1. January 2020

How is a modern ROTWILD frame created?

ROTWILD E-MTB frame concepts are packed with technical features technical features, innovative details and provide the basis for bikes consistently bikes designed for function. Not only the shape of the E-MTB frames, but above all their but above all their technology and the development and manufacturing process behind manufacturing process set new standards again and again. The frames made entirely of carbon carbon frames stand for our will to continue the outstanding quality and performance the outstanding quality and performance of the bikes in every new project. develop.

Precision in every production step

More than 60 hours are required from the laying of the first carbon layer to the finished painted frame, and the entire production process is highly meticulous manual work. Around 35 specialists have the frame in their hands during this time and devote themselves to its completion with great precision in their area of responsibility.

All carbon layers are carefully applied by hand - as here at the shock mount on the top tube.

The entire production process is based on close cooperation between the ROTWILD developers and the engineers at the frame builder. This is because once the new design has been completed, the development phase begins on site, lasting a good six months, during which a major focus is placed on building up the layers, aligning each individual carbon layer and running through testing requirements for all components.

The production of a frame is divided into several process steps, starting with the cutting of the carbon layers. After a rough cut, the exact shape is cut using CNC-controlled cutting machines.

Precise shape cutting by means of CNC-controlled cutting machines.

1,046 individual carbon blanks

A frame of the ROTWILD R.750 series consists of 1,046 carbon blanks, each one carefully developed and designed in its shape to the loads of the associated frame sections. A layer of carbon consists of two layers with a combined thickness of 0.2 mm, depending on the necessary wall thickness and component, several are laminated on top of each other.

One of over a thousand carbon cuttings required for a single frame. Designed exactly in position and dimension for the respective frame section and cut to fit precisely.

Here, the specialists join together layer by layer according to the exact specifications of a layout plan. Reusable silicone molds serve as the basic shape, but metallic components such as the swing arm bearing are also wrapped with several carbon layers in this way - the experts refer to this as "preforming". Nothing happens here by chance, quite the opposite. In addition to the number of carbon mats placed on top of each other, the alignment of the fiber orientation is of great importance. This follows the preceding simulations of forces.

The individual components, such as the masonry pipe here, are built up layer by layer.

Working with shapes

The finished components are placed and fixed in a metal mold, which somewhat reminiscent of a baking mold, and fixed in place. The whole thing then goes the oven, where the frame is given its final shape and stability under high pressure and temperatures frame takes on its final shape and stability. Careful work is also required to remove the frame from its metal mold. metal mold. Subsequent finishing by hand involves cleaning off burrs and removing the burrs and removing the hoses and silicone components required for molding from the silicone components from inside the frame.

Each frame size requires its own mold, in which each frame is "baked" under pressure and temperatures around 80° C. Silicone molds provide a wrinkle-free and snug-fitting surface on the inside of the frame. After "baking", these must be removed from the frame by hand.

A special feature of the new ROTWILD bikes: Due to the complexity of the frame, this consists of two parts, for each frame size are therefore necessary for the main frame two molds. These weigh several hundred kilos each and consist of over 30 individual parts.

The main frame is first produced in two parts in the molds and then assembled.

After hardening and cooling, the two-piece main frame is main frame is assembled into one component and the surface is smoothed. The entire production process is accompanied by permanent quality checks. quality controls. Each individual component is intensively inspected and checked for its and checked for accuracy of fit and processing tolerances.

The upper and lower halves of the carbon frame are joined in a separate gauge. Clearly visible is the Integrated Carbon Motor Case, which will house the Brose Drive S-Mag later in production.

Check again and again

An important step and a special feature is the recurring check in the X-ray machine, spot checks in the production process process allow a view inside the frames and thus a permanent check of the production of the manufacturing processes. In addition In addition to road tests, extensive testing is carried out with prototype frames prior to series release and the start of production. extensive testing with prototype frames. The frame spends several days per test the frame spends on a test rig and undergoes several 100,000 load changes. load cycles. These dynamic load tests of individual components and of the frame include fatigue tests, e.g. cradle pedaling, control of stiffnesses and the stiffness and impact behavior.

Permanent quality controls throughout the entire manufacturing process are an essential part of guaranteeing the high quality of ROTWILD frames. This also includes X-raying selected components, such as the front frame triangle here.

Last but not least

At the end of the production process, there is a complex finish in several including priming, masking, multiple painting and application of the decor painting, and application of the decoration - until the typical ROTWILD deer head sits in its place.

Representative of all technical innovations, he wears the ROTWILD deer head with pride on the head tube, the new R.X750 frame.

Learn even more about carbon processing in our article: Know-how: Not all carbon is the same und Know-how: Visible carbon structure on the biker frame.