Everything starts with the mold. We take an OEM part — the actual stock piece from the bike — and build a precision mold around it. This guarantees the carbon part we pull from it matches the factory geometry exactly. Wrong mold means wrong fitment, so this step gets obsessive attention.
The mold is built from fiberglass and gel coat, sealed and finished until it's smooth enough to produce a part with a clean surface right out of the mold.
Once the mold is complete, it gets inspected. We check every edge, every curve, every mounting point recess. Each mold gets a part number and bike model labeled on it — we know exactly what it makes, every time.
A finished mold can pull dozens of parts over its lifespan without degrading. Consistency is the point — part 1 and part 50 should look identical.
The 200gsm bi-directional carbon fibre sheet goes into the mold by hand — one layer at a time. Then aerospace-grade epoxy resin is applied at a strict 1:1 fibre-to-resin ratio. Not 1.2:1. Not 0.9:1. One to one.
This ratio is critical. Too much resin means excess weight and brittleness. Too little and the structure fails. 1:1 gives maximum rigidity for minimum weight — the same standard used in racing composites and aerospace.
After layup, the part cures under controlled conditions. No shortcuts on cure time.
Out of the mold, the part gets trimmed, edges refined, and the finish applied. Gloss gets a UV-protective clear coat. Matte gets a satin finish that keeps the weave visible without the shine.
Then it goes through QC. We check the surface for voids, delamination, edge finish quality, and fitment tolerance. If it doesn't pass — it doesn't ship. That's the only standard we operate by.
"If we wouldn't put it on our own bike, it doesn't ship."
