The material: premium fiber meets nano
In order to achieve our ambitious goals, it was clear to us from the very beginning that we had optimize all the available adjusting screws. In our “raw material”, the carbon fiber itself, only high-end fibers of the quality T800 were thus used for ROADSAILOR, which are also manufactured in Germany. Adapted to their individual characteristics, we developed a high-strength nano-resin, which optimally connects the microstructures of the individual fabric threads and thus gives the rims even more strength.
The construction: UD carbon meets carbon fabric.
ROADSAILOR Bikes consist of at least 92 percent of unidirectional (UD) carbon fibers of premium class. In contrast to braided carbon fabric, this material cannot accumulate any superfluous resin in the interstices of the fiber crossings and thus increase the weight. In addition, UD fibers can be aligned more flexibly, making double layers unnecessary. Nevertheless, we also use woven fibers where they can prove their excellent characteristics: as a reinforcement on the rim base and in the rimbed.
Processing: Know-how meets innovation.
Almost 20 years of experience in handling carbon have not hindered us from questioning what has been proven. The result were many, partially unconventional improvements in detail. As a conseqeunce, ROADSAILOR rims are formed from a continuous fabric layer, which helps to avoid overlaps and thus superfluous weight. By means of special pressure lines in the curing process, we have increased the strength of the rim edges and thus improved the emergency running properties. There is neither a pressure hose nor a foam core in the rim housing: for reasons of weight, but above all, in order to not provide the heat produced by the brakes with a heat accumulator.
Production: time saves weight.
The processing of carbon requires the use of heat and pressure to harden the material. ROADSAILOR has therefore developed a complex process that divides the curing process into seven cycles with individual temperature and pressure additions. Each ROADSAILOR rim is cured for more than four hours. With manufacturers in Far East this work step often lasts less than 40 minutes. However, in order to achieve similar strength values, numerous additional fabric layers are then required.
Production: time creates safety.
Carbon is one of the most stable materials, given its properties. As a result, the grinding of brake flanks was just as out of the question as the drilling of spoke holes: Both production processes cut through the sensitive fibers. This reduces their strength, but above all the getting rid of brake energy is interrupted, which can lead to serious damage of the rims. Even if the ROADSAILOR processes are significantly more time-intensive: the structures of the material remain completely intact at the reinforcement of the brake flanks as well as when “displacing” the carbon fibers for the rim holes.
The finish: the black silver arrows.
The legend of the silver arrows in motorsport is based on a necessary weight reduction: In order to meet the limits for racing cars, the paint of the cars was sanded overnight. The bare metal remained as the surface. What does this have to do with us? Well, our wheels are also designed for maximum performance. When looking more closely at our ROADSAILOR rims, their marbled surface structure changes constantly. But these are no defects, but are the state of the art of modern technology. Of course, like others, we could paint the surfaces to fill minimum unevenness or achieve a uniform hue. For various reasons we do not want to do this: On the one hand, the lacquer limits the thermal conductivity of the fibers. On the other hand, see the beginning.