Introduction to the innovative Fusion fiber technology used by Forge and Bond for bike wheel production.

• Fusion fiber is a new material used by Forge and Bond based in Utah for manufacturing bicycle wheels.
• The material offers key advantages over traditional carbon fiber in terms of manufacturing and performance.
• The presenter plans to explain the advantages and the manufacturing process inside the Forge and Bond factory.

An overview of how traditional carbon fiber products are manufactured and the drawbacks of the process.

• Traditional carbon fiber manufacturing involves using prepreg carbon, which must be kept frozen until use.
• The manufacturing process is labor-intensive, and the material has a limited shelf life.
• A significant amount of material waste is generated, which cannot be easily recycled.

Exploring the Fusion fiber material and its benefits over traditional carbon fiber for wheel manufacturing.

• Fusion fiber uses nylon instead of epoxy resin, eliminating the need for refrigeration and allowing easier handling.
• Nylon's thermosoftening property allows the material to be heated and reshaped multiple times.
• The manufacturing process is more precise and efficient, with a robotic system minimizing waste and increasing speed.

Delving into the detailed process of manufacturing a wheel using Fusion fiber material at Forge and Bond.

• The process begins with cutting carbon fiber pre-impregnated with nylon into swatches.
• A machine called the Fiberon heats and fuses the swatches together to create the wheel's structure.
• Excess material from the wheel is trimmed off, and the 2D part is forged into a 3D shape using a press.

The final steps in the Fusion fiber wheel manufacturing process, leading to the completed product.

• After the wheel is forged, it is laser-trimmed and the halves are bonded together.
• The bonded wheel is then cured in a heated press, removing the need for extensive surface finishing.
• Finally, the wheel is drilled for spokes and valves, assembled with a hub, and it's ready for use.

Advantages of Fusion fiber in terms of ride quality and the environmental benefits of the material's recyclability.

• Nylon as the matrix in Fusion fiber provides better vibration dampening, enhancing bike wheel ride quality.
• Fusion fiber's recyclability allows waste material to be repurposed into other products, reducing environmental impact.