Development and manufacturing of CFRP bicycle components and fiber composite parts – from idea to series production.
all ahead composites GmbH
97209 Veitshöchheim (DE)New on Amplifa
About all ahead composites
all ahead composites GmbH, based in Veitshöchheim near Würzburg, develops, designs, calculates and manufactures components made of carbon fiber reinforced plastic (CFRP). Under the BIKE AHEAD COMPOSITES brand, the company produces carbon wheels, frames, handlebars, stems, seat posts and seat parts for road bikes, gravel bikes, mountain bikes and triathlon. The entire value chain from idea to series product takes place under one roof in Germany. Manufacturing processes include prepreg autoclave, RTM, RIM, VARIM and hand lamination; in addition, the patented NO SLIP APPLICATION with an NBR rubber layer applied during the manufacturing process is used. Alongside its own product range, all ahead composites develops and manufactures CFRP components for partners from aerospace, racing and medical technology. All parts undergo 100% quality inspection; in-house test benches simulate the operational loads.
- Site
- Veitshöchheim
- Processes
- Prepreg production (prepreg autoclave process), Autoclave curing (autoclave), RTM (Resin Transfer Molding), RIM (Reaction Injection Molding), VARIM (Vacuum Assisted Resin Infusion Molding), Hand lamination process (hand laminating process), NO SLIP APPLICATION (patented application of an NBR rubber layer directly during), FEM analysis and development/design of CFRP components
- Materials
- Carbon Fiber Reinforced Plastic (CFRP), Fiber reinforced plastic (general), NBR rubber (special rubber layer for NO SLIP APPLICATION), Prepreg (pre-impregnated carbon mats), Pre-impregnated Carbon Mats (Prepreg), NBR Rubber (NO SLIP APPLICATION), Resin Transfer Molding (RTM), Reaction Injection Molding (RIM)
- Founded
- 2010
- Industries
- Bicycle industry (road, gravel, MTB, triathlon), Aerospace, Racing, Medical technology, Bicycle components (road, gravel, MTB, triathlon), Fiber composite technology/CFRP manufacturing for aerospace, racing,
- 01
Development and design (CAD)
- 02
FEM analysis
- 03
Tooling/Preparation
- 04
Lamination (prepreg, RTM, VARIM, hand lamination)
- 05
Curing (autoclave, RIM)
- 06
NO SLIP APPLICATION
- 07
Quality inspection (100% inspection)
- 08
Load simulation and fatigue testing
- 09
Shipping/Distribution
Materials and Processes
Carbon Fiber Reinforced Plastic (CFRP)
Core material for wheels, frames, cockpits and custom fiber composite parts offering lightweight construction, stiffness and durability.
Pre-impregnated Carbon Mats (Prepreg)
Material for the prepreg autoclave process with low weights at high strength.
NBR Rubber (NO SLIP APPLICATION)
Special rubber layer that is bonded directly to the component during the manufacturing process and reduces clamping torques in clamp areas by up to 60%.
Resin Transfer Molding (RTM)
Resin infusion process for fiber composite components with defined surface quality.
Reaction Injection Molding (RIM)
Reaction casting process for processing reactive resins.
Vacuum Assisted Resin Infusion Molding (VARIM)
Vacuum-assisted infusion process for CFRP components.
Hand Lamination Process
Manufacturing process for components where an optimized production process is required.
Autoclave Process
Curing of prepreg laminates at high pressure and high temperatures for low weights at high strength.
Locations
Veitshöchheim
DEDevelopment, Production, Distribution, Headquarters
- Materials
- CFRP, prepreg, NBR rubber
- Autoclave
- CAD workstations
- In-house test benches for load simulation
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Prepreg production (prepreg autoclave process)Plastics | – | – | – | – | CFRP (carbon fiber reinforced plastic), Prepreg |
| Autoclave curing (autoclave)Plastics | – | – | – | – | CFRP, Prepreg, NBR rubber (NSA layer) |
| RTM (Resin Transfer Molding)Plastics | – | – | – | – | CFRP (fiber composite), Resin |
| RIM (Reaction Injection Molding)Plastics | – | – | – | – | Resin (reactive resin) |
| VARIM (Vacuum Assisted Resin Infusion Molding)Plastics | – | – | – | – | CFRP (fiber composite), Resin |
| Hand lamination process (hand laminating process)Plastics | – | – | – | – | CFRP (fiber composite), Resin |
| NO SLIP APPLICATION (patented application of an NBR rubber layer directly during)Surface | – | – | – | – | NBR rubber, CFRP |
| FEM analysis and development/design of CFRP componentsEngineering | – | – | – | – | CFRP |
| Quality inspection of all parts (100% inspection) and fatigue tests on in-house test benches (testTesting | – | – | – | – | – |
| Contract manufacturing of CFRP products and components for partners from research and industryPlastics | – | – | – | – | CFRP |
3 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Autoclave | – | – | – | – | Veitshöchheim |
| CAD workstations | – | – | – | – | Veitshöchheim |
| In-house test benches (test benches for load simulation) | – | – | – | – | Veitshöchheim |
Additional services
Reference customers
Company History
- 1994
Founder Christian Gemperlein receives his first mountain bike; beginning of his interest in bicycle technology and the material carbon
- 2010
Foundation of all ahead composites GmbH by Christian Gemperlein in Veitshöchheim
- 2025
15th company anniversary with the Limited Editions BITURBO Edition 15 and THE SUPERFAST Edition 15