READING TIME 5 MINUTES
TIME bikes are crafted like nothing else in the bike industry. Our Braided Carbon Structure (BCS) road and gravel bike frame construction is more time-consuming and complex than traditional molded carbon frames and is among the most advanced carbon fiber bike frame manufacturing techniques in the world. Similar braided carbon structures are seen in Formula One, aerospace, and military applications, prioritizing no-compromise performance and consistent precision manufacturing.
Let’s take a deeper look at how BCS differs from more common carbon frame construction methods.
Traditional Carbon Construction vs Braided Carbon Structures
Most mass-produced carbon frames are made one way: a variety of “pre-preg” (meaning fibers are pre-soaked with a thick, sticky resin) carbon fiber pieces are cut into shapes and hand-stacked into a mold with an internal air bladder for support before being baked into a frame.
TIME’s BCS construction involves carbon fiber, resin, and molds, but that’s where the similarities stop. We start with dry fiber strands placed into a machine that braids them into carbon sleeves. A specifically shaped internal mandrel is inserted into the sleeve, and the entire assembly is sealed into a mold. Resin is injected under heat and pressure—a process known as Resin Transfer Molding—which thoroughly saturates the carbon with resin before curing.
Pre-Preg Pros and Cons
Cyclists are told that pre-preg molded carbon construction is the best way to make a high-performance carbon fiber bicycle, as it places layers exactly where they’re needed, thus optimizing the structure. This is true to an extent, but the downside to pre-preg, hand layup composite air bladder construction is that there can be considerable variance in quality and accuracy with each frame, as the seams between the various stacked carbon layers present opportunities for voids, inconsistencies, resin pools, and weak spots.
Using Advanced Fibers in Advanced Ways
Though Braided Carbon Structure road bikes like the TIME ADH Disc might visually appear similar to the cosmetic “3K” carbon fiber patterns you see in everything from bottle cages to headset spacers and smartphone cases, this is next-level, advanced carbon fiber bike technology.
BCS utilizes a sophisticated three-dimensional machine-braiding technique that integrates carbon fibers at multiple orientations in a complex and exact manner impossible to create with human hands. This creates a lattice of continuous, unbroken fibers throughout the length of the structure. Sixteen different types of fibers can be precisely incorporated into the structure, and the entire network of fiber works in unison to manage the myriad of stresses seen during riding. By combining exotic high-tech fibers like Kevlar™, Vectran™, and bio-based Dyneema™, the World’s Strongest Fiber, in a way that’s not possible with pre-preg construction, TIME engineers can dial in a ride feel that is exceptionally well suited to gravel cycling where compliance, vibration damping, and durability are critical.
By using a hard internal mandrel (made of proprietary wax that is later melted out of the finished frame) and the high-precision RTM process, TIME can consistently produce flawless frames both inside and out.
Next-Level Durability and Impact Resistance
We’ve all heard the tale of someone’s top-of-the-line carbon bike tipping over at a coffee shop and suffering a catastrophic failure. Conventional composite frames often suffer from brittleness and reduced impact resistance in real-world circumstances, and manufacturers attempt to mitigate this by adding unidirectional carbon layers at different orientations in high-impact zones. This is a delicate balance, as these reinforcing layers add weight and affect ride quality.
In contrast, TIME’s intertwined, three-dimensional BCS construction and the related Resin Transfer Molding (RTM) process enhance bonding between fibers, resulting in a more cohesive structure that can absorb and dissipate impact energy more effectively. BCS frames are more resistant to fatigue stress and less likely to suffer from failures after minor incidents and impacts. The result: a tougher frame with more carbon fibers focused on enhancing the overall performance and ride.
BCS is Rare for Good Reason
Why aren’t more bicycles made with BCS construction? It takes longer and requires some exotic machinery. BCS and RTM construction require precise tooling and machinery, and the process takes more time and labor per frame than traditional mass-manufactured frame designs.
Moreover, braided carbon structures are typically reserved for cost-is-no-object pursuits in other industries, such as aerospace, military applications, and Formula One racing, where top performance and reliability are non-negotiable. This niche status underscores the exceptional quality and engineering behind BCS technology, distinguishing it from the more commercially viable options prevalent in consumer cycling.
Taking the Time to do Things Better since 1987
There are quicker, easier, and cheaper ways to make carbon bicycle frames. That’s just not what we do. At TIME, we have a guiding principle: Le Defi, or “The Challenge” in French. Since 1987, we have challenged ourselves to make the most refined bicycles on earth. We believe that our Braided Carbon Structure road bikes represent the pinnacle of advanced carbon fiber technology, and for cyclists who prioritize performance, ride quality, and long-term reliability equally, is isn’t just the best way to make a high-performance carbon fiber bicycle. It’s the only way.
