Exoskeleton Technology
The traditional methods of creating carbon fibre frames and forks followed the methods used when artisans still created beautiful bikes from steel.
With the development of monocoque molding processes frame designers were able to create modern bikes that began to benefit from the unique material properties of carbon. But there were still flaws.
Utilizing detailed Finite Element Analysis conducted during the research and development process, our designers and engineers first developed the unique profiles in the Diablo frame and forks, and then refined the exoskeleton technology – incorporating continuous C6.7 carbon fibres integrated into the monocoque front triangle.
Stiffness ribs were also included in strategic locations on the fork blades, chain and seat stays to achieve the required performance, comfort and handling characteristics.
During the analysis and development phase, calculations of the mechanical behaviour of each tube and joint within the Diablo were based on an energy principle (i.e. to minimise the deformation) and resulted in a stiffness matrix, key to describing the mechanical behaviour of the structure. This matrix specified the reaction forces at the nodes when they were subjected to a set of known displacements. The global force equilibrium was generated at each node in order to determine the unknowns. Once the calculation process is completed the method determined the actual stresses in the elements and the displacements due to the loading specific to the pedaling action.
The design created allows carbon fibre to run continuously through tube-joint-tube transitions, resulting in a frameset that has been optimised for its unique material characteristics.
C6.7 uni-directional high modulus carbon fibre
With the development of monocoque molding processes frame designers were able to create modern bikes that began to benefit from the unique material properties of carbon. But there were still flaws.
Utilizing detailed Finite Element Analysis conducted during the research and development process, our designers and engineers first developed the unique profiles in the Diablo frame and forks, and then refined the exoskeleton technology – incorporating continuous C6.7 carbon fibres integrated into the monocoque front triangle.
Stiffness ribs were also included in strategic locations on the fork blades, chain and seat stays to achieve the required performance, comfort and handling characteristics.
During the analysis and development phase, calculations of the mechanical behaviour of each tube and joint within the Diablo were based on an energy principle (i.e. to minimise the deformation) and resulted in a stiffness matrix, key to describing the mechanical behaviour of the structure. This matrix specified the reaction forces at the nodes when they were subjected to a set of known displacements. The global force equilibrium was generated at each node in order to determine the unknowns. Once the calculation process is completed the method determined the actual stresses in the elements and the displacements due to the loading specific to the pedaling action.
The design created allows carbon fibre to run continuously through tube-joint-tube transitions, resulting in a frameset that has been optimised for its unique material characteristics.
C6.7 uni-directional high modulus carbon fibre
Finite Element Analysis of tube profiles in raw frame Exoskeleton technology in Diablo Prototype: R01:V01 Diablo front triangle mold Stiffness ribs design in Diablo Prototype: R01:V04