Carbon Fiber Technology

Carbon Fiber Expert

Not all carbon fiber is equal—choose the true expert.

Carbon Fiber Technology

Ride Lighter,Ride Faster,
Ride Carbon Fiber.

Carbon fiber: a feather-light yet planet-strong material once reserved for aerospace. Now, carbon fiber eBikes deliver faster, smoother, and happier rides. Say goodbye to heavy, clunky bikes—welcome advanced technology built for you. The future is here, where cutting-edge innovation meets everyday affordability.

Discover why carbon fiber outperforms aluminum for e-bike frames—lighter, faster, and built for performance. Click here to read our blog post,【Carbon Fiber vs. Aluminum E-Bike Frames】, and make a smarter choice for your ride.

Carbon Fiber Technology

Ride Carbon Fiber,
Ride

Not all carbon fiber is equal—choose the true expert. Urtopia pioneers carbon fiber technology and craftsmanship, delivering eBikes that redefine performance and value. Through relentless innovation, advanced automation, and scalable production, we push the boundaries of quality and affordability. Trust Urtopia—your carbon fiber expert.

Compared with traditional aluminum frames, carbon fiber frames offer a lighter and faster riding experience. Click here to read our blog post, 【Carbon Fiber vs. Aluminum E-Bike Frames】, to fully understand the advantages of carbon fiber and make a more informed choice.

3 Core Technologies
of Urtopia

Carbon Fiber Technology

3D CFF

3D Carbon Fiber Fabrication

An advanced textile technology that weaves carbon fibers in three dimensions, creating complex, layered structures.

Carbon Fiber Technology

ECF

Endless Carbon Fiber Technolology

Non-interrupted continuous carbon fibers, unlike short or long carbon fibers that have breaking points, ECF woven carbon cloth has no breaks offering excellent strength.

Carbon Fiber Technology

RAF

Robotics Automated Formation

Carbon fiber production method leveraging on the incredible capability of robotics to lay the carbon fiber strand in complex pattern in super efficient way under high quality.

300+ Professional Media
Outlets Give High Praise

Carbon Fiber Technology

Urtopia’s achievements have earned widespread acclaim, including the GOOD DESIGN Award in Japan. Over 300 top-tier outlets—USA Today, Cyclingnews, Engadget, TNW, TechCrunch, CNET, Forbes, EBR, and Digital Trends—have featured Urtopia.

Forbes: “A true flyweight in e-bikes. It’s even lighter than my non-electric mountain bike.”
CNET: “You won’t find a bike much lighter with more tech baked in than the Urtopia.”

8 Steps to Urtopia
Carbon Fiber

1. Weaving and Pre-Impregnation

We select race-grade Toray T1000 carbon fibers and weave them at various angles based on design needs. Our proprietary resin, enhanced with silane coupling agents, improves wetting and curing. Lab tests show this optimized resin densifies the fabric—boosting strength by 5.7%, reducing weight by 4.3%, and cutting delamination risks, potentially extending lifespan by over 50% for enhanced safety.

2. Cutting and Sorting

During carbon fabric processing, we employ an advanced automated system that precisely cuts, sorts, and codes the fabric based on input dimensions without manual labor. This system reduces the industry’s typical error rate of 0.6% to 0%, minimizing human error and ensuring consistent quality and performance.

3. Pre-Forming

In the pre-forming stage, we use CAE (Computer Aided Engineering) and FAE (Finite Element Analysis) to aid the design of lamination. Experienced technicians then follow procedures to attach hundreds of pre-cut carbon fabric pieces onto an EPS inner mold. Our unique stacking design optimizes strength, weight, rigidity, and shock absorption— the essence of our carbon fiber frame. Specially shaped patches reinforce areas with varied stress, ensuring stability under complex loads. Consequently, frames with the same exterior can perform differently due to their stacking design.

4. Molding

Molding is a key step in forming carbon fiber products. Using high-precision molds and controlled temperatures, the fibers and resin cure perfectly. Unlike traditional splicing, our partner’s exclusive MonolithTM one-piece molding forms the entire frame in one process. This directly half the molding time as instead of 2 or 3 pieces of molds now we only do this once for one frame. Less machine time implies shorter production lead time and lower overall cost.

5. Machining

The Monolith™ technology offers a dual advantage: cost - effectiveness and remarkable performance. Traditional bike frames require gluing and curing, leaving behind heavy and unappealing junctions, which can also create weak points. In contrast, products made with MonolithTM are crafted in one seamless piece. This not only results in a frame with an elegant shape and smooth surface, but also brings about a significant weight reduction. Frames using this technology are over 11.7% lighter; for example, a road bike frame weighs just 583g without any comprimise on the performance.

6. Comprehensive Reliability Inspection

Each frame undergoes eight rigorous reliability tests. Our long-term investment in testing equipment and quality control ensures potential issues are identified and resolved during production. We perform comprehensive X-ray inspections to detect subtle defects, such as internal carbon fiber delamination, voids, and tiny foreign inclusions, ensuring the frame’s overall reliability and quality.

7. Painting

Painting is the final step in our frame production. After thorough cleaning, we apply a primer and bake the frame at a controlled low temperature for proper curing. Then, we add decals and a topcoat, followed by another low-temperature bake to achieve the final finish. This process improves paint adhesion, durability, and overall lifespan, ensuring no quality issues due to carbon fiber’s unique properties.

8. Quality Inspection

Our factory adheres to ISO9001 and TS16949 standards, using automotive-grade quality controls. After 37 thorough inspections of each frame’s appearance and dimensions, the product is packaged and shipped. This rigorous process enhances reliability and safety, ensuring every consumer can trust our product.

Carbon Fiber Technology

Urtopia Carbon E-Bikes

1

Gram Lighter
Second Faster

Riding a carbon fiber eBike is not just a commute but a cultural shift, a selection of life style. When you hop on a Urtopia carbon fiber eBike, it’s like a whole new world opens up. It’s not just about getting from point A to B; it’s about the smooth, light, and super - strong ride. You feel the difference right away, whether you’re zipping through city streets or cruising on country roads.

In a divided world, Urtopia offers unity. It’s a vision where excellence is shared, innovation is constant, and the road ahead is a portal to endless possibilities.

Ride carbon fiber, ride Urtopia.

Learn more
Carbon Fiber Technology

3D Carbon Fiber Fabrication – 3D CFF

3D carbon fiber weaving technology is an advanced textile process that interlaces carbon fibers in three-dimensional space to form a fabric with a 3D structure. Building on conventional 2D weaving techniques by incorporating axial fibers, specialized weaving equipment and processes are used to interlace and twist carbon fiber yarns in a predetermined pattern, creating a complex 3D structure.

By interweaving the carbon fiber threads, the final product is less prone to delamination while exhibiting excellent torsional resistance—ideal for bicycle frames designed to handle complex road conditions and varied applications. Additionally, machine weaving eliminates the inefficiencies and inconsistencies of traditional manual carbon cloth layup, maximizing the benefits of automation and continuous production to enhance quality and reduce costs.

Carbon Fiber Technology

ECF - Endless Carbon Fiber Technolology

Infinite-length carbon fibers refer to continuous fibers that are significantly longer than 100mm with no breaks. They differ from short carbon fibers (SCF), which are under 10mm and used in plastic composites, and from conventional long carbon fibers (LCF), typically cut to around 100mm. The advantage of infinite-length carbon fibers is that the resulting woven carbon fabric is made from a few continuous fibers without any breakpoints, ensuring excellent continuity and superior strength.

There are two production methods: one uses 3D printing to form continuous carbon fibers with the help of a plastic substrate for core strength and support; the other employs a textile-like weaving process to create carbon fabric according to specific panel sizes. By reducing fiber breakage, these methods achieve superior mechanical performance with the same material weight.

Carbon Fiber Technology

RAF - Robotics Automated Formation

RAF revolutionizes carbon fiber production by integrating industrial six-axis robotics for unmatched precision and efficiency. These robotic arms, with their six degrees of freedom, move with elegance and accuracy, laying continuous carbon fiber strands in complex patterns guided by advanced software. This automated process ensures high consistency, eliminates human-induced errors, and significantly reduces waste, making production more sustainable.

The speed of these robots is transformative, drastically shortening production cycles and meeting growing market demands faster than ever. By seamlessly integrating with other manufacturing steps, RAF enables scalable, consistent production of high-performance carbon fiber components. This innovation isn’t just keeping pace with the times—it’s setting new standards. Every carbon fiber product crafted by these intelligent machines delivers reliability, strength, and innovation, ready to take on the world.