Scroll
Power Frame: the e-bike revolution starts with forged carbon
Born in Reggio Emilia, in the heart of the Motor Valley, Carbotronics’ Power Frame represents a new paradigm for e-bikes. At the core of this project is a clear vision: integrating power directly into the bike frame, leveraging the full potential of a cutting-edge technology: forged carbon CF-SMC (Carbon Fiber Sheet Molding Compound). This is a composite of short, pre-impregnated carbon fibers, molded using high-precision heated molds.
The result? A robust, lightweight monocoque frame capable of housing a power unit inside.
The first fully integrated e-bike solution.
European
Product 1
The Carbon Forging technology
The bike industry consumes some 5 million frames a year, 99% of those coming from Taiwan and China as the conventional lamination process is extremely labor intensive and time consuming.
We don’t question of course the mechanical characteristics of a frame in laminated carbon, we do challenge however the limited engineering of that process and searched for alternatives to build carbon frames in Europe. Born in the Motor Valley where sport cars and motorbikes are made, the company has developped its technology to build frames through forged carbon CF-SMC (Carbon Fiber Sheet Molding Compound). This is a composite of short, pre-impregnated carbon fibers, molded using high-precision heated molds.
What are the benefits of a frame in Carbon Forging?
The SMC is an isotropic material that allows for CAE simulation in the design stage. It’s widely used in the sport car industry.
The process occupies little labor (you don’t need to lay the carbon fibers on the mold one by one as in the case of lamination) and is very fast (a frame in 20 minutes instead of many hours).
The process guarantees repeatability, consistent quality, and scalable production.
Short development time, short supply chain at costs competitive to current Chinese production.
Italian technology for reshoring carbon frame production
When the motor is off
Product 2
The Zero Drag Technology
We have developped a light and powerful power (110 Nm) unit with specific focus on riding experience and quietness (less than 60dB) featuring the patented “Zero Drag” system, which eliminates motor resistance above 25 km/h or when the motor is off. The result is a natural, fluid experience, it feels just like riding a traditional bicycle.
The patented “Zero Drag” system allows the rider to transfer full power directly to the rear wheel. The electric motor and drivetrain are mechanically disengaged from the spider.
When the motor is off or the speed exceeds 25 km/h, there is no drag—only the pedal axle rotates.
This results in an unprecedented level of pedaling smoothness.
Easy maintenance. The power unit is divided into two sections: mechanical and electronic, both easily accessible via two separate covers.
Opening the electronics side reveals only the control board with just two connectors.
Opening the mechanical side reveals the reduction gear, pedal axle, torque sensor, and signal board.
Only five spare parts in total.
Product 3
The Power Frame Technology
With know how on power unit and on carbon forging frames, our third product is the integration of power within the carbon frame. We name that the Power Frame. With no visible mounting points and a seamless fusion of structure and power, the Power Frame is likely the lightest, smoothest, and quietest e-bike you’ve ever tried. Made in Europe at costs competitive with Chinese manufacturing.
From the very beginning, the goal was to create an innovative and truly one-of-a-kind product—designed to deliver the most natural riding experience possible, with the added benefit of pedal assist.
What are the benefits of the Power Frame?
We are used to see aesthetic integration of power units within bike frames. The Power Frame goes beyond that providing a structural integration. You pedal on the frame and not on a motor attached to the frame.
The elimination of conventional connecting pins between the motor and the frame allows for weight reduction and improved frame rigidity.
The integration of the motor components within the frame allows at last an improved lay-out, for example to reduce the exposure of the driver to the motor heat improving the overall performance under stress.
The Power Frame is protected by international patents.
The first Power Frame has been built integrating Carbotronics Power Unit and Carbotronics frame but we are already collaborating with qualified global power unit suppliers, to develop power frames accessible to all.
OUR DEVELOPMENT HISTORY
Contact Us!
