OUR DEDICATION TO QUALITY

Tavelo is committed to delivering top-quality bikes that meet the highest standards of production. Our focus on craftsmanship and attention to detail ensures that every bike we create provides an exceptional riding experience. We believe in the importance of durability and performance, making sure our customers can rely on their Tavelo bike for all their adventures. Join us in the journey towards quality and excellence in cycling!

QUALITY ASSURANCE IN THE PRODUCTION OF CARBON BIKES

The production of high-quality TAVELO carbon frames is quite complex. Depending on the model, a frame can be lay up of as many as 300 carbon fiber pieces, each precisely shaped to bear the load of different parts of the frame.

From bare thread to finished, it takes over 60 hours to complete and painted. Around 35 specialists from different departments are involved in the process. Given all this, quality assurance plays a critical role throughout.

The carbon fiber reinforced plastic (CFRP) used in the frame must meet the highest standards for strength, stiffness, appearance, and weight. To achieve this, seamless quality control is essential. By documenting every production step in detail, improvements can be made, and errors avoided.

CONTROL OF RAW MATERIALS

Quality control begins with the inspection of the raw materials used and their manual or mechanical processing. This is the only way to produce frame components that meet all the specifications from the design and withstand the calculated loads. In addition, conscientious quality control in series production ensures that the properties of all frame components remain the same.

The properties of frame parts made of CFRP material depend heavily on careful manufacturing. After a component has been completed, possible production defects such as defective material or unclean alignment of the carbon layers can only be detected with extremely high effort. In the course of quality control, efforts are therefore made to eliminate material defects and defective parts from the manufacturing process as early as possible.

QUALITY ASSURANCE IN FRAME MANUFACTUIRNG

For quality assurance during the construction of the all TAVELO frame, there are clear standard operating procedures (SOP) for each process step. These procedures cover the inspection of all workpieces, auxiliary materials, operating materials and work instructions. The specific quality inspection can be divided into three steps:

1. Incoming Materials Inspection

2. Inter-departmental Quality Control and Quality Assurance in Process

3. Final Quality Control

Incoming Materials Inspection

Flawless materials are the foundation for ensuring the high quality of the final product. This step focuses on checking whether the various raw materials are free of defects, ensuring they can be used in production without hesitation. The inspection includes carbon fiber prepregs, fiberglass mats, resins, molds, EPS cores, metal inserts, threaded inserts, headset bearings, screw fittings, inlays, frame components, and packaging materials (protectors, decorative, and protective films).
Cutting

Flawless materials are the foundation for ensuring the high quality of the final product. This step focuses on checking whether the various raw materials are free of defects, ensuring they can be used in production without hesitation. The inspection includes carbon fiber prepregs, fiberglass mats, resins, molds, EPS cores, metal inserts, threaded inserts, headset bearings, screw fittings, inlays, frame components, and packaging materials (protectors, decorative, and protective films).
Lay up

To ensure error-free production, every lamination step is thoroughly detailed in the layup plan with both text and images. For easier tracking, each frame is assigned a unique QR code.
Molding

At this step, quality assurance defines the curing parameters. These include mold contact pressure, internal pressure, the temperature profile, and curing time.
Quality control after demolding (blank)

This step ensures that the molds and tools used for frame components are not mixed up. A visual inspection of the frame blank is conducted, with special attention to the following: resin buildup (lack of fiber), wrinkling, delamination, contamination, dents, holes, cracks, damage from demolding, and the condition of the mold. To detect even the slightest production defects, testing is also performed in a water tank. The air-filled frame blank is submerged, and any bubbles that emerge reveal poorly bonded areas between carbon layers, which could compromise structural integrity, leading to rejection of the part.
CNC machining

At this step, CNC machines are used to process various frame components. Each machining step is precisely detailed, listing the CAM programs to be used, along with the specifications for milling tools and coolant to ensure high product quality. After each machining step, measuring tools and test gauges are used to inspect the machined surfaces, ensuring that all dimensions and interfaces meet the required standards.
Bonding

The jigs, adhesives, as well as the bonding temperature and time for gluing frame components are all specified. Every step is thoroughly documented to ensure that all processing requirements are met accurately.
Fullness & slurry

Once all the dimensions of the frame blank have been adjusted, the surface is sanded. During this process, the surface finish is continuously checked by visual inspection. The frame only meets the required standards once all burrs are removed and all surfaces are smooth.
Quality control - handover to the painting department

Before painting the frame blank, we perform another visual inspection. We pay special attention to any color variations in the visible carbon fiber and fabric defects, ensuring the surfaces are smooth. We look for holes caused by missing material, scratches, dents, drips, and bubbles. We also check all edges to make sure they match the design intent and that no areas have been overly smoothed due to excessive sanding.
Painting

To ensure quality, the cleaners, primers, colors, and masking films used during the painting process are precisely calculated. Colors and artwork are carefully planned, and after each intermediate step, another visual inspection is performed to ensure everything meets the required standards.
Decals

After painting, labeling takes place. All decals have specific guidelines, including size, position, color, and material. During application, a visual inspection is conducted to check the number, type, and placement of the stickers. If everything is correct, the final layer of paint is applied (matte or gloss finish).
Quality Control After Painting and Decal

Once all painting and decal are complete, a final visual inspection is carried out to ensure there is no paint damage, defects, fading, unwanted matte or gloss effects, orange peel texture, drips, bubbles, scratches, dents, or misalignment and incompleteness in patterns and decorations. Additionally, the surface thickness, impurities (particle density), hardness, and durability (through a drop-ball test) are checked.
Frame Weight and Surface Finishing Inspection
Head Tube Inner Tolerance, Length
Bottom Bracket Tolerance, Roundness Inspection
Frame Brake Mount Position
Width of Chainstay and Seatstay, Tire Clearance
Fork Weight and Surface Inspection
Width of Fork, Tire clearance and Center placement of wheel
Fork Brake Mount Position
Seatpost Size

OUR DEDICATION TO QUALITY

QUALITY ASSURANCE IN THE PRODUCTION OF CARBON BIKES

CONTROL OF RAW MATERIALS

QUALITY ASSURANCE IN FRAME MANUFACTUIRNG

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