EPS process (Expanded Polystyrene Molding Process) is an advanced technology used for manufacturing carbon fiber bicycle frames. This process can help manufacture lighter, stronger, and more precise carbon fiber frames.

In the traditional manufacturing of carbon fiber frames, inflatable bags (bladders) are usually used for internal mold forming, but EPS process uses expanded polystyrene foam as the internal mold. During the molding process, the carbon fiber cloth layer will be covered with EPS foam, and the frame will be solidified and shaped under high temperature and pressure conditions. Finally, the internal foam will be removed to form a hollow frame structure.

The specific steps of EPS process include the following key links:

1.Calculate the direction of force and material stacking: Firstly, use software to calculate the direction of force on the frame and determine the stacking method of carbon cloth to ensure the strength and rigidity of the frame.

2.Making EPS inner mold: Use polystyrene material to make the inner mold and fill it into the predetermined position of the frame. This internal mold serves as the foundation for molding, ensuring the precise shape and size of the frame.

3.Carbon fiber lamination: Based on the EPS inner mold, carbon fiber materials are stacked layer by layer, and through hot pressing and curing processes, the carbon fibers are tightly combined with EPS to form a sturdy frame structure.

4.Demolding and subsequent processing: After completing the lamination, remove the EPS inner mold, trim and surface treat the frame, and finally obtain the finished frame.

The main advantages of EPS technology include:

- Smooth inner wall: compared with the traditional inflatable airbag process, EPS foam inner mold can achieve a more accurate internal shape, making the inner wall of the frame more smooth and reducing excess resin accumulation.

- Lightweight: Due to the more precise inner walls, the frame requires less resin and materials, thereby reducing the weight of the frame.

- More uniform structure: Through more stable mold support, the carbon fiber layer is subjected to more uniform forces during the curing process, reducing defects such as bubbles and wrinkles, and improving the overall strength and consistency of the frame.

- Reduce waste: Due to the high precision of the inner mold, the cutting and laying of carbon fiber fabric are more accurate, reducing material waste in production.

EPS technology is gradually being applied to high-end carbon fiber bicycles because it can provide higher structural strength, lower weight, and better riding performance.