Process

Contact us

Email info@ukcarbonfibrerepair.com to discuss requirements; including attachment of images along with a brief description of the component in order for us to understand the extent of damage and provide an accurate quotation.
Components are sent to us either by an arranged courier to collect components from anywhere in the U.K or the customer may arrange their own delivery by dropping the parts into our workshop. Open 9am-6pm.

The Delivery

The Inspection

Along with taking into account the customer provided details of the circumstances and incident resulting in the damage, the severity of damage is assessed. A report is finalised and a quotation is confirmed with the customer.  Parts are individually tested and closely examined using a combination of methods. We use a variety of acoustic tools that provide a quantified frequency readout used to detect de-laminations that are not revealed by visual inspection.

Surface cracks and damage within the frame are measured, documented and examined. We have a range of tools and instruments in the workshop to measure lengths, diameters and thicknesses, physical measurements such as frame alignment and dimensions can be determined. The rest of the component is also checked to ensure that no further damage is present. A rigidity test measures the stiffness values, determining if the weakness can explain by the visible damage. There can be additional thermographic measurements taken to see any possible hidden damages. Once we have confirmed fractured internal fibres are present and all damaged areas have been found, we uncover the damage by sanding and removing the paint and outerlayer. (As the repair can de-laminate and would be weaker if layered straight up onto paint.)

Depending on the shape of the part we may need to create and prepare a mould to maintain its form. Carbon layers are gradually and carefully removed in ever smaller areas. This is necessary in order to avoid abrupt changes in stiffness along the tube. The bottom layer is not removed as this provides a required area for rebuilding of carbon available. The damaged area is then thoroughly cleaned and degreased to ensure a good bond of the new layers.

The Preparation

The Ideation

Planning of the CFR layer-up. Our Engineers use sophisticated software programs and expertise that take into account the grade of carbon, the resin, the shape, size and orientation of the carbon-fiber ply. We’ve resourced the best materials and frequently use a combination of different carbon fibre to achieve the best structural integrity.
For example bicycle frames are optimized for extreme lightness and/or rigidity.
Using special epoxy, and carefully calculating the correct amounts of fibre and matrix. The fibers are laid using a wet-lay process. The vacuum ensures that the fibres are well connected and the air is excluded between the layers.

The Production

Preparing the finish

After curing, the repair site is unpacked sanded and cleaned. The frame is now ready for painting, but first the stiffness values are measured again to determine if the measurements meet the relevant specification.
The finish. The frame is painted according to the customers requirement.
Basic – Here you can leave the carbon fibres visible,
Premium – The component is restored to match the original paint and graphic scheme.
Bespoke – The customer requires a complete different paint design and graphics to before.
added extras – while your bikes in for repair we can also offer a full bicycle service in our workshop.