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COMPOSITE CLINIC – 8th Edition – taken from Giant Australia FACEBOOK

The hand crafting of each Giant Bicycles composite frame at their C-Tech Composite manufacturing facility is a labour intensive process, our Advanced Composite frames take about nine hours from start to finish. However, Advanced SL composite frames take twice as long (up to 18 hours) due to the addition of a third step to the moulding process – FUSION MOULDING

What does fusion moulding mean? You may have heard of the term “co-curing”. Giant’s process utilizes co-curing methods but in a very specific manner that is proprietary and unique. Fusion is used in only ONE section of the Advanced SL ISP frames; the Integrated Seat Post. The Integrated Seat Post is joined at the junction of the top-tube and the seat-tube by filament winding — essentially hand-weaving the two tubes together. This filament-wound area of the Integrated Seat Post is then re-moulded under heat and high pressure to unify the junction.

The result is a lighter, stronger junction, saving up to 150 grams. Other manufacturer’s frames might be dove-tailed here, where the top tube is butted into the seat tube and then glued and perhaps lugged, adding precious grams to the overall frame weight. Fusion is an expensive, labour-intensive process, adding significantly to the time required to construct an ISP frame but yield performance gains in ride quality and weight saving to the finished product.


Cyclemania owner and director of  Lion Sports Management, Wayne Evans is over at the Tour assisting his Athletes with contract negotiations. It is not all work as shown from a few of his photos taken as they wait for the race to flash by….

“Long hot day sitting on an embankment by the road side yesterday for 6 hours waiting for the riders to come past.  Kev the kangaroo attracted lots of attention and had his photo taken numerous times.  Great atmosphere, fun people watching and talking to all different  nations. The Orica Green Edge car also stopped and gave us their famous guitars to play with too. Cheers Wayne”

giant fibre


This week we dispel the myths on the “chequered” carbon finish seen on many bicycle frames…..
The weave pattern you see on many Giant and other brand’s bicycles and consumer products is a Carbon Fibre thread fabric weave. The composite material used in the construction of the frame looks nothing like this. The “chequered” material is typically applied as an outer layer outside the tubes. Outside it serves little use other than aesthetics. Like paint colours, it is a visual choice and one that people have easily associated with what they perceive as “Carbon Fibre”.

As seen on Giant Australia Facebook



Info from Giant Australia FACEBOOK post

There is a common misconception that riders in the pro-peloton ride special one-off, race only composite frames that your everyday cyclist could only dream about. In some instances this may be the case!

When you are watching the Belkin Pro Cycling Team at this year’s Le Tour De France you will see them riding TCR Advanced SL, Trinity Advanced SL and Propel Advanced SL frames made at the Giant Bicycles C-Tech Carbon Fibre Manufacturing facility as all of our production composite frames are.

From the raw Toray T-800 carbon fibre thread used in our own composite sheets, to the lay-up schedule and quality control inspections, every step is the same for both the composite frames for the pro-peloton and for you the consumer.

What does this mean for you? You can buy the very same frameset that you will see our team riders on in tonight’s stage of The Tour from your local authorised Giant retailer.

Cyclemania is an authorised Perth GIANT bicycle dealer so contact us for more information

Giant bikes perth

See more at HERE on their Facebook page


Q: What is involved in Giant’s proprietary moulding process?

A: Once the “lay up” process has been finalised it is time for the “soft” frame to be placed into a clamshell-like steel mould. These moulds are manufactured specifically for each model and size of Giant bicycle.
These moulds are then put into a high-pressure, high-temperature oven for the frames to “cook” under strictly controlled conditions.

During this process, precise amounts of Giant’s proprietary resin matrix that were impregnated into the lay up swatches are expelled to leave just the right amount of resin remaining in the finished frame. If you leave too much resin in the frame, then you have an inconsistent frame, with voids and heavy pockets of resin. This makes the frame heavy and inconsistent in its final ride quality. If you remove too much resin, you can still have voids and you are left with a weak, unsafe frame.

Giant carefully control the three critical elements of the moulding process, temperature, pressure and time. The precise use of these three elements ensures consistent results in manufacturing composite frames.

Stay tuned next week when we go into greater detail about the critical elements of the moulding process!

Giant part 4

See more at HERE on their Facebook page

Part 4 of Giant Bicycles Australia 7 part series on carbon fibre manufacturing. Great reading. See the Facebook page for previous episodes and we will be posting the new ones as they are released.


Q: What does the layup process entail?

A: The layup process is the second step in the composite frame construction process, and it’s where the mechanical engineers take over from the chemical engineers. Giant’s mechanical engineers designate really how the bike will ride, and how strong it will be, as well as how light it’s going to be.

The Pre-Preg sheets then go to the Lay-up room, where they are cut into swatches. To handcraft one composite Giant bicycle, more than 500 individual swatches are positioned onto “soft” frames.

Each swatch is a specific shape and size, and they must be precisely positioned by hand around the soft frame according to a “Lay-Up Schedule.” The exact “Lay up” is a top secret schedule determined by Giant’s mechanical engineers. Change any part of the layup, and you change the entire ride quality and structure of the bicycle. Quality control inspections during the layup ensure that doesn’t happen.

You can lay-up a swatch in one direction, and it’s designed to take on a specific form. When you lay-up in another direction, the swatch has high tensile strength. It has less flexibility, but it is more weight-bearing or load bearing.

In the case of Giant’s Advanced SL grade frames, Continuous Fiber Technology (CFT) is employed, using longer, larger – and therefore fewer – swatches of composite in the front triangle. With fewer pieces and junctions, the frames are up to 200 grams lighter, significantly stronger, and have greater vibration dampening properties. CFT is more expensive, and it’s more labour intensive – which is why it’s found only on our top of the line Advanced SL grade frames.

Stay tuned for the 5th edition of Composite Clinic next week!

Our stomping Grounds

Cyclemania owner and director of  Lion Sports Management, Wayne Evans is in Europe to assist Cameron Meyer prepare for the upcoming tour de Suisse and the tour de France. Last year, Wayne and his wife Melissa spent 3 months over in Andorra with Cameron and his brother Travis. This year Wayne has gone over to help Cameron get into top condition for the above mentioned races.

Wayne and Cameron can be seen daily along the roads of Andorra and Spain. Travis and Wes Sulzberger can be seen occasionally joining them on some epic mountain rides.

Click on Gallery images to enlarge

New products in-store arriving daily
  • Perth’s Newest BONT Dealer. Cyclemania are stockists for BONT cycling shoes. These are light stiff and very comfortable and can be tailored to your foot in a custom mold
  • We are Perth’s Newest KASK helmet dealer. Wear the same helmet as TEAM SKY. KASK (as well as us here at Cyclemania) also sponsor Perth’s very own pro cycling team, the SATALYST GIANT RACING TEAM. They are supreme fit with leather straps and lightweight.
  • Cyclemania are stockists for TIFOSI sunglasses. These glasses have photocromatic lenses with adjustable temples for a better fit.
  • We now stock GIRO shoes and gloves.
  • Cyclemania are now premium stockists of VOLTA clothing. We have a full range available of winter clothing to aid you through the wet months.
  • We are also now stocking BLANCO TEAM clothing. Get your GIANT bike with the matching team kit to boot!
  • Cyclemania are now stocking SPEEDPLAY pedals and cleats
  • We now stock many brands of power measuring devices like SRM and QUARK. Come in to get advice on your next training device
  • Cyclemania Team Gear made by SEIGHT is now on order. Get your sizing done and get in quick as it is simply the best kit you will buy this year.