Estimating Wall Thickness of Carbon Composite Bike Frames

To better understand how much carbon is necessary in the bike frame I was constructing, I studied photos of existing frames which had been cross-sectioned or cut away. These can be found on Google.


The red and yellow lines were draw in PowerPoint (below).

The yellow line was used to scale the photo to make measurements. A known distance was measured, for instance a head set or bottom bracket seat diameter (standard diameters are found on Park's website here and here). Then the red lines were measured and a simple proportion was used to scale them to the photo. Perspective made this difficult, but a reasonable estimate (within an order of magnitude?) was possible.

So in certain areas like the head tube gussets, main tubes, and areas around the BB and ST/TT intersection I was able to estimate the wall thickness of these production frames... and approximate ply quantity. I tabulated and averaged these estimates in a spreadsheet.





Here are the composite frame cutaway photos I found and measured:






































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