Home Cycling Allied Cycles Manufacturing unit Tour – Bikerumor

Allied Cycles Manufacturing unit Tour – Bikerumor

Allied Cycles Manufacturing unit Tour – Bikerumor


Since our first go to to Allied Cycle’s authentic manufacturing facility in Little Rock, rather a lot’s modified. They moved close to Bentonville, giving them entry to far more trails, and their course of has been regularly refined as they’ve added new fashions. The most recent is the BC40 XC mountain bike, named for the large Again Forty path community there.

On this manufacturing facility tour, Allied’s gross sales supervisor Will walks us via how they make their frames, together with the linkage elements for the MTB, and the way that differs from their street bikes. Test the video for the total story, and scroll down for extra element pictures and notes.

Allied Cycles Manufacturing unit Tour Photographs

allied cycles showroom

Enter the constructing and also you’ll discover their showroom, the place you’ll be able to see among the bikes, try merch, and pickup a demo bike. They hold a dimension run of every mannequin out there for check rides. Allied Cycles can be open for excursions to anybody, simply make a reservation upfront when you’d prefer to stroll via this course of in individual.

allied cycles carbon cutting room

Step one in making the frames is reducing the carbon. They’ve an automatic cutter that reads a pc program to reduce waste. Every body part is minimize in a gaggle then bagged collectively and kitted within the trays and racks.

allied cycles carbon layup room

From there it goes into the layup room, the place workers layup one tube or part at a time.

allied cycles employees laying up carbon fiber bike frames

Every individual is skilled on one a part of the bike for a minimum of six weeks, turning into an professional at that half’s layup.

allied cycles internal soft molds

The carbon items are laid up over smooth, re-usable silicone mandrels.

allied cycles internal soft molds

To make them agency sufficient to wrap carbon round, they fill them with grains. This offers them simply sufficient form for laying up the pre-preg carbon fiber, and as soon as that’s achieved, the grains are dumped again out in order that the molds might be pumped stuffed with air as soon as they go into the press.

allied cycles carbon frame parts before molding

Every mandrel has a port the place excessive strain air can go in, which is able to press the inside mildew in opposition to a CNC’d aluminum outer mildew.

allied cycles carbon frame parts before molding

Some small elements and joints, just like the BC40’s shock mount, are made by stacking layers of 3K woven carbon quite than the UD sheets used for many of the body.

allied cycles pass through door from layup to molding rooms

As soon as it’s all pieced collectively and within the mildew, it passes via this door into…

allied cycles heat presses

…the press room. Right here, the molds are hooked as much as the air strains and inserted into warmth presses. These heat the insides to soften the resin whereas the air strain squeezes the carbon layers in opposition to the steel mildew. This pushes out any air and extra resin and primarily glues the entire layers collectively completely.

allied cycles kitted frame parts

As soon as it cools, the molds are open and out pops the body half. Within the case of the BC40, all the entrance triangle is made as a single piece, and all sides of the rear triangle is one piece.

allied cycles kitted frame parts

The street and gravel frames are made in sections, then bonded collectively. The entire elements are made in batches and kitted collectively, then they transfer over to the following space to be assembled and have any steel elements bonded into place.

allied cycles frame parts bonding and assembly

Allied makes use of steel threaded backside brackets, and people are bonded into place to completely connect contained in the BB shell.

allied cycles frame parts bonding and assembly

The tubes are sleeved to suit collectively. They use a bonding agent to connect them collectively, then overwrap every joint with a layer of carbon fiber. Then it’s again into an oven to treatment the bonding glue and overwrap, primarily creating one single unit.

allied cycles finishing and assembly station

As soon as the body is wanting like a body, it goes via a collection of checks for alignment and cable cross via. Now’s the time to repair any little points. They wish to ensure the entire hoses, wires, and cables will slide all through any inside routing ports earlier than it will get sanded and painted!

allied cycles sanding and finishing room
allied cycles frame filler application

As soon as it passes that QC verify, it strikes on to sanding and ending. All flashing is eliminated, after which frames are coated in a light-weight filler to clean any small imperfections from the molding course of. That is achieved in order that they’ve a layer to sand clean earlier than paint with out having to sand the carbon. That’s vital as a result of Allied doesn’t add a beauty outer layer of carbon fiber, and so they can’t sand the carbon itself. So this filler is utilized everywhere in the body, after which largely sanded off.

allied cycles robot sander


allied cycles robot sander test frame


allied cycles frames waiting for paint

As soon as that’s achieved, the frames are prepared for portray. Proven above are bikes prepared for his or her first layer of paint, which is able to turn out to be the colour of any logos or graphics.

allied cycles paint room

Allied paints all of their logos utilizing a two-step course of. First, they paint a base coat coloration that may present up because the logos. After that’s dry, vinyl graphics are utilized to masks off the logos, then it goes again within the paint sales space for the ultimate (outer) paint coloration.

allied cycles paint example

As soon as that coat is dry, the masking stickers are pulled off, revealing the logos. So, for this bike above, it was painted neon yellow first, then masked, then painted in racing inexperienced. Eradicating the masking revealed the intense yellow logos. There aren’t any decals on the completed product, it’s all paint. (Facet be aware: Using filler for sanding and smoothing is why Allied doesn’t supply frames unpainted or exhibiting the uncooked carbon)

allied cycles bicycle assembly room

As soon as they’re painted and verify, they transfer into the meeting room. Allied sells to outlets and sells direct, however they’re all assembled on this room.

allied cycles bikes boxed and ready to ship

Then they’re boxed and prepared for pickup, heading to a cheerful rider someplace!

Enormous because of Will, Drew, Cole and the remainder of the crew for exhibiting us round and taking us for a experience!




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