The Additive Fusion Technology (AFT) is a new manufacturing standard allowing you to produce cycling components out of continuous fiber composites in small to high volumes with competitive costs vs. aluminium.
AFT is an open-source platform allowing materials from reliable suppliers with a global footprint rather than relying on materials from limited or even a single supplier. It also makes a positive impact by greatly reducing wastage encountered in heritage manufacturing due to offcuts and off-spec parts — particularly with thermoset matrices whose scrap cannot be reused. With its combination of an additive manufacturing and a fusion process, it enables you to reduce the weight of bike parts by at least 50% while remaining cost competitive vs. aluminum.
AFT also helps address cost and time to market via fully virtual design optimization and validation (digital twin). By prototyping with electrons rather than steel and composite, not only are costly materials used more efficiently, but it eliminates the old iterative loops of make & break (design parts, build prototype tools, mold and test parts, and start again). Leverage the most advanced software and manufacturing technologies, engineered in Switzerland. Be independent from established supply chains.
Versus conventional manufacturing, AFT reduces material usage and scrap due to unmatched design freedom, more precise fibre-layout control, and the ability to produce net-shape parts. Printing itself is energy efficient. Printed preform functionality is further increased and secondary operations eliminated when hardware is insert molded or preforms are injection/compression overmolded.
Using open-source thermoplastic materials allows recycle offal, and increases material-selection options, including use of recycled/upcycled polymers, polymers from biobased monomers, and recycled fibres, further increasing circularity and sustainability.
Unique surfaces can be created, combining technical and aesthetic performances.
AFT directly address manufacturing costs by reducing both scrap (thanks to higher design freedom, more efficient fiber layout control, and the ability to print net-shape parts) and labor (through highly automated and repeatable operations that enable quality to be verified in real time as parts are printed and formed).