Monolith moulding
Monolithic moulding is a patented method whereby a frame is moulded in one session. This is genuine monocoque! Traditionally, a frame is divided into several compartments that are joined together after pressing.
Technology
With Monolith, the entire frame is built as one. This allows the carbon layers to run along the classic ‘junctions’ without interruption. These critical transitions are thus optimized in terms of strength and stiffness without having to compromise on weight.
2022: Next level Prorace Bikes thanks to the addition of Nano Tech
From 2022 onwards, CNT (Carbon Nanotybe Technology) will be used in addition to the EPS method during production. Thanks to this technology, our current carbon fibre combined with the carbon nanotubes form a composite material which results in a strong, elastic and isotropic material with good resistance to fatigue.
These carbon nanotubes have very good mechanical properties. For example, the tensile strength is 100 times bigger than steel and the density is only 1/6th of steel. The result? A light, but enormously strong frame.
Besides the Carbon Nanotube Technology, all frames are still produced according to the EPS (Expanded Polystyrene System) technology to further increase the stiffness and tolerance of critical parts of the frame.
Less carbon, yet 30% stronger
All Prorace frames are produced using EPS technology to guarantee light, yet strong frames. The EPS system allows us to use less carbon than other systems and to still give the perfect compression in all corners of the frame.
To press the carbon layers to the inside of the mould we use EPS (Expandable Polystyrene) sections. These are formed to exactly match the internal shapes of the frame.
Further we wrap the polyurethane frame in pre-impregnated carbon fibres and place them in the mould.
When the mould is heated, the polyurethane disappears, these EPS sections expand and push the carbon layers against the mould, forming a smooth and airtight carbon wall. We call this system ‘Ghost mould Technology’. Both the inside and outside of the frame have the same smooth finish.
This process ensures the best possible construction in terms of weight, stiffness and strength. Especially in combination with MONOLITH technology, which makes the frame one piece.
The result is a PRORACE frame of exceptional strength and quality. Each frame is also thoroughly checked for rigidity to ensure it has the right carbon layering. In addition, every hundredth frame is given a full EN test. Whereas other carbon manufacturers only use 3 different frames, 1 for each test, at Prorace all 3 tests are carried out on each frame: the “fatigue” test, the flex test and the impact test. Prorace also demands that the tested frames are 30% stronger than what is normally required.
