The complete AX Lightness operation takes place within this modern building in Creußen, Germany - Oli Woodman/Future Publishing
This component is a brake duct that AX Lightness built for Sebastian Vettel's Toro Rosso Formula One car. It dates back to a time when most of the company's work was within the motorsport industry - Oli Woodman/Future Publishing
AX Lightness have previously produced components for various forms of motorsport, from Formula One and Le Mans cars to Superbikes - Oli Woodman/Future Publishing
This carbon fibre tank has been produced in a shape that would be extremely difficult to replicate in alloy - Oli Woodman/Future Publishing
Sebastian Vettel photographed with AX Lightness managing director Axel Schnura - Oli Woodman/Future Publishing
Bicycle components sit alongside Formula One suspension arms in a bizarre but beautiful archive kept on display in the office - Oli Woodman/Future Publishing
AX Lightness produce both mountain bike and road bike componentry - Oli Woodman/Future Publishing
Some components are significantly more recognisable than others - Oli Woodman/Future Publishing
Carbon fibre wheels for an Audi? Not a problem for AX! - Oli Woodman/Future Publishing
Katrin Leumann's Ghost Factory race bike, as used in the 2012 Olympics - Oli Woodman/Future Publishing
AX Lightness have already toyed with the idea of hydraulic discs on a road bike, as seen on this Vial disc prototype - Oli Woodman/Future Publishing
Through-axle fork for the Vial disc prototype - Oli Woodman/Future Publishing
The chainstay of this Vial disc prototype has been moulded to neatly integrate a SRAM Red hydraulic disc calliper - Oli Woodman/Future Publishing
The carbon fibre arrives in sheet form, it is pre-impregnated with resin and is stored at around -17C to prevent the resin from curing before the fabric is used - Oli Woodman/Future Publishing
The carbon fibre sheet is stored at around -17 degrees centigrade, this is to prevent the resin from curing before the fabric is used - Oli Woodman/Future Publishing
Carbon sheets are loaded onto this CNC cutter, which is capable of cutting intricate shapes for minimum waste - Oli Woodman/Future Publishing
The cutter operator plots the correct cutting program via the computer - Oli Woodman/Future Publishing
The cutter then gets to work, cutting the desired sections from the carbon sheet - Oli Woodman/Future Publishing
Once the cutting is complete, each section can simply be seperated from the original sheet... - Oli Woodman/Future Publishing
...it is then loaded into a box that connects the cutting room to be picked up by workers at the next stage of the process - Oli Woodman/Future Publishing
The layup stage takes place in a clean room - an environment with a controlled climate and conditions that prevent dust - Oli Woodman/Future Publishing
Larger components are layed up in aluminium moulds, but the smaller parts, such as these saddles, use carbon moulds - Oli Woodman/Future Publishing
A worker applies the carbon in layers according to a 'plybook' - a diagram that lists what material goes where and in which direction - Oli Woodman/Future Publishing
Lay-ups are determined and optimised through knowledge, prototyping and testing - Oli Woodman/Future Publishing
A light adhesive is applied to further adhere the layers, but no resin is applied because it is already pre-impregnated into the carbon fibre - Oli Woodman/Future Publishing
Depending on the component, either vacuum bags or inflatable bladders are used, this applies pressure to the layers - Oli Woodman/Future Publishing
Here, a section of rim hooks have been layed up and are ready for curing - Oli Woodman/Future Publishing
The resin is cured using an autoclave, essentially a pressurised oven that produces components of significantly higher quality than a regular oven - Oli Woodman/Future Publishing
The autoclave minimises the number of gas bubbles forming in the resin as well as reducing unwanted build up of resin (known as resin rich areas). It also allows for a longer and more gradual curing process. All of these things make for a better final product - Oli Woodman/Future Publishing
When parts emerge from their moulds and the curing process, they require finishing, as seen on this freshly finished batch of stems - Oli Woodman/Future Publishing
The raw components are then cut and sanded as necessary - Oli Woodman/Future Publishing
AX lightness do not add unnecessary clear coat to their components, instead they are polished to the final finish - Oli Woodman/Future Publishing
AX Lightness rims are built using large alloy jigs such as this one - Oli Woodman/Future Publishing
Building a wheel from scratch is a labour-intensive process that typically takes around 7.5 man hours - Oli Woodman/Future Publishing
Spoke holes are moulded at this stage - Oli Woodman/Future Publishing
The spoke holes are reinforced to the extent that they can deal with more tension than any spoke can currently achieve - Oli Woodman/Future Publishing
Moulded spoke holes complete with reinforced carbon sections - Oli Woodman/Future Publishing
Spoke tension is so high that AX Lightness' hub suippliers have to use reinforced bodies to deal with the extra forces - Oli Woodman/Future Publishing
The rims are then sealed tightly, and both heat and pressure are applied to cure the resin - Oli Woodman/Future Publishing
Optimum pressure and heat conditions ensure the resin remains fluid for a long time and that it cools gradually rather than suddenly - Oli Woodman/Future Publishing
Once you understand the work involved in creating such a rim, the retail prices start to seem justified - Oli Woodman/Future Publishing
Fabric carbon fibre is used instead of the unidirectional variety, this is because of its far superior heat dissipation properties - Oli Woodman/Future Publishing
AX Lightness make a wide variety of rims, from deep aero road rims to mountain bike clinchers - Oli Woodman/Future Publishing
So new that it hasn't even got a name yet! These leather topped carbon creations tip the scales at just 87g - Oli Woodman/Future Publishing
The carbon shell of this new saddle is shaped so that once the leather sections are glued into place, the transition between the two materials is seamless - Oli Woodman/Future Publishing
Raw carbon saddle porn - Oli Woodman/Future Publishing
We popped one on the scales and confirmed that its weight is just 87g - Oli Woodman/Future Publishing
We first heard about the Vial EVO at last year's Eurobike show. Now the frameset that will be under 700g for all sizes is nearly complete - Oli Woodman/Future Publishing
The Vial EVO should be arriving for March and will be available as a frameset from €3,000 - Oli Woodman/Future Publishing
AX lightness opted for a press-fit BB386 bottom bracket shell - Oli Woodman/Future Publishing
The BB386 bottom bracket uses no sleeves, instead a special carbon lay-up allows the bearing to be pressed in directly, without removing material. This alone saves more than 30g - Oli Woodman/Future Publishing
Here is a custom frame that was being built for a customer. The layup of every tube was unique to the customer's requirements. The target weight is 630g - Oli Woodman/Future Publishing
Every tube was chosen and built from this customer's individual requirements - Oli Woodman/Future Publishing
Carbon fibre frames can look a little scary during manufacturing - Oli Woodman/Future Publishing
Minimal dropouts for this 630g frame - Oli Woodman/Future Publishing
A plysheet sits on top of two halves of a mould for the front triangle of a frame - Oli Woodman/Future Publishing
AX Lightness also produce carbon frames for other manufacturers - Oli Woodman/Future Publishing
The recent addition of a paintbooth will allow AX to toy with new finishes for their parts and frames - Oli Woodman/Future Publishing
This modest paintshop was frequently occupied by a man who was responsible for painting Bugatti's Veyron. He was brought in to train an AX employee to spray - Oli Woodman/Future Publishing
This room holds stock in preperation for quality control inspection - Oli Woodman/Future Publishing
A batch of quality control approved saddles - Oli Woodman/Future Publishing
Various components awaiting inspection and that all-important quality control approval sticker - Oli Woodman/Future Publishing
The quality control sticker lists an accurate weight, a manufacturing date and inspector,s signature - Oli Woodman/Future Publishing
AX Lightness' Zeus stem: probably the lightest stem in the world, yours for €739 - Oli Woodman/Future Publishing
Many options means a lot of stock - Oli Woodman/Future Publishing
Rims werenot in short supply - Oli Woodman/Future Publishing
Currently AX Lightness employ just one wheel builder to assemble all of their wheels - Oli Woodman/Future Publishing
Another wheelbuilder will soon be required - if you're interested, visit the AX Lightness website! - Oli Woodman/Future Publishing
Engage brakes prepared for inspection. Engage are the sister brand of AX Lightness. Engage components are designed, checked and assembled in Germany but are built in Asia - Oli Woodman/Future Publishing
Throughout the building are various toys. Here is MD Axel's KTM motocross bike - Oli Woodman/Future Publishing
Next to the christmas tree is another toy - a Ducati 1098 racer complete with custom carbon goodness - Oli Woodman/Future Publishing
More toys. This time a 1940s Harley Davidson motorcycle - Oli Woodman/Future Publishing
Another look at the '40s Harley - Oli Woodman/Future Publishing
Here are just a few examples of AX Lightness' extensive product range - Oli Woodman/Future Publishing
Carbon crank arms - Oli Woodman/Future Publishing
Ultra light carbon calliper brakes - Oli Woodman/Future Publishing
Completed parts are polished to offer a mirror-like shine - Oli Woodman/Future Publishing
Saddles from the range can weigh as little as 55g - Oli Woodman/Future Publishing
€590 will bag you this RIGID stem, suitable for both road and mountain biking use. A 70mm example weighs just 68g - Oli Woodman/Future Publishing
As with many lightweight components there are weight limits. This stem is safe for a rider up to 95kg - Oli Woodman/Future Publishing
The Zeus stem is an incredible bit of engineering. This example (excluding steerer bolts) tipped the scales at 59g - Oli Woodman/Future Publishing
The €739 price sounds steep, until you learn there isn't a lighter model in production - Oli Woodman/Future Publishing
The lightest production road bike frame available is about to emerge from a small industrial estate in Germany, yet, aside from dedicated weight weenies, few riders will have heard of AX Lightness, the brand behind it.BikeRadar recently visited the AX Lightness factory in Creußen, and discovered what is perhaps the best kept secret in carbon fibre.
When people talk about carbon frames and components, the last place that'd normally spring to mind would be Germany. But AX Lightness has been producing all of its components in-house within Germany for over a decade.
The complete ax lightness operation takes place within this modern building in creußen, germany: - Oli Woodman/Future Publishing
AX Lightness don't just manufacture bicycle components. Just a few years ago, most of the company's time was occupied with work from car manufacturers and motorsport. It even produced complex carbon fibre components for Sebastian Vettel’s Formula One car!
Take a look at their current product range and you'll find an extensive line-up of both road and mountain bike components.
Here are just a few examples of ax lightness' extensive product range: here are just a few examples of ax lightness' extensive product range - Oli Woodman/Future Publishing
Everything is carbon and many of the products are the lightest you'll find anywhere. It's no wonder that AX Lightness components were used on what is still believed to be the lightest bicycle ever built.
Company founder Axel Schnura's original focus was on little more than producing the absolute lightest components available, but the firm has since undergone a shift in its thinking. The aim now is to not only produce the lightest parts but to also produce the best. AX Lightness learned that it could add useful ergonomic features, improved practicality and function to many of its components while only adding minor figures to the overall weight.
These tweaks are slowly bringing AX Lightness away from its roots in niche weight weenie-ism, yet it's fair to say that all of this kit is top-shelf: Keith Bontrager's aphorism of "strong, light, cheap; pick two" applies perfectly. However, for those who want AX Lightness design at a more affordable price, there are Engage components.
Engage brakes prepared for inspection. engage are the sister brand of ax lightness. engage components are designed, checked and assembled in germany but are built in asia: - Oli Woodman/Future Publishing
Engage is a sub-brand from AX Lightness, and all Engage parts are designed by AX but made in Asia. It's important to mention that all Engage parts are subject to the same stringent quality control as regular AX Lightness component and, as a result, each Engage part is inspected and assembled in Germany.
Whether you're a wealthy weight weenie or not, AX Lightness is definitely a brand to look out for. Check out our image gallery for an exclusive tour behind the doors of the AX Lightness factory.
Former BikeRadar staffer Oli is passionate about anything with wheels and/or an engine or motor. A keen eye for technical detail and a general curiosity for how things work often gives Oli a unique insight into products he's either testing or writing about. An unhealthy interest in older motor vehicles keeps him poor but happy.
This website is owned and published by Our Media Ltd. www.ourmedia.co.uk
