Braided Carbon Structure (BCS)

Perfection Woven into Every Strand

In the world of carbon fiber bicycles, there are two paths: the ordinary way, and the Sunremo way. For over twenty years, we have advanced an entirely proprietary approach to engineering — a philosophy centered on structural continuity rather than piecemeal assembly. This commitment finds its ultimate expression in our “Braided Carbon Structure”, produced on custom machinery designed and built entirely in-house.

Structural Integrity Through Continuous Fibers

Our Braided Carbon Structure represents a fundamental departure from conventional sheet-based layup. We engineer fibers into seamless, tubular, bi-directional sleeves. This three-dimensional architecture enables precise material tuning — Sunremo selects from a curated library of 16 distinct filaments to tailor each layup to its specific performance mandate.

The result is a breakthrough in composite integrity: continuous, uninterrupted fibers that traverse the entire length of a structural element. Visualize the structural coherence of multiple woven layers flowing without break from the steerer tube, through the fork crown, and into the fork legs—achieving unity with minimal joints. Compare this to the inherent vulnerability of standard prepreg construction, where every cut edge represents a discontinuity and a potential point of stress concentration.

Multi-Material Synergy for a Superior Frame

True “material architecture” is possible because BCS begins with dry fibers. Resin is introduced only during molding, liberating us from the constraints of pre-impregnated sheets. Within a single, coherent weave, we can strategically integrate high-modulus (HM) carbon for stiffness, high-strength (HS) carbon for resilience, or materials like Kevlar® for impact resistance. When next-generation fibers such as Vectran® are developed, Sunremo’s dry-fiber process allows for rapid prototyping and integration.

Conventional prepreg construction is constrained by the limited, proprietary material systems of individual suppliers. Combining materials across these closed systems is impractical, often limiting even the most complex frames to two or three primary fiber types, such as standard HM and HS unidirectional or woven carbons.

Our Engineering Palette: An Infinite Spectrum of Materials

High Modulus Fibers

  • Role: To deliver precise, localized stiffness and pedaling efficiency.
  • Specification: Fiber tensile modulus of 360–450 GPa.
  • Examples: Carbon M46 JB, Carbon M55 JB, Carbon UMS 65.

High Strength Fibers

  • Role: To provide the optimal balance of durability, fatigue resistance, and responsive feel.
  • Specification: Fiber tensile strength of 3.5–4.8 GPa, with a failure strain >1.5%.
  • Examples: Carbon T700S, Carbon T800, Carbon IMS 65.

Ultra-High Strength & Specialized Fibers

  • Role: To impart exceptional toughness, damage tolerance, and vibration damping in critical zones.
  • Specification: Fiber tensile strength of 3.0–6.0 GPa, with exceptional failure strain >2.8%.
  • Examples: Vectran®, Aramid (Kevlar®), Zylon®, Pyrofil®.

Uncompromising Control & Precision

The flexibility of dry braided sleeves grants our engineers unparalleled command during the layup process. Material can be sculpted, tensioned, and positioned with absolute precision to ensure perfect fiber alignment and consolidation, free of wrinkles or voids. Prepreg, by contrast, is adhesive and unforgiving; its application on complex curves demands fragmentation into countless small patches, creating a quilt of seams rather than a unified whole. The difference is akin to tailoring a garment from cloth versus assembling it from rigid, pre-glued tiles.

Directional Morphing: The Art of Performance Tuning

The true genius of BCS lies in its tunability. Through “Directional Morphing”, we can locally alter the weave geometry—strategically stretching or compressing the sleeve along the tube axis during layup. This elegant technique allows us to graduate stiffness and compliance *within a single, continuous piece*, calibrating ride quality with surgical precision. Prepreg methods attempt to mimic this by piecing together angular patches, but these inherent seams create mechanical discontinuities and stress risers absent in our monocoque braided structures.