Carbon

Carbon fiber is now the most widely used material for building high-end bicycles. All production is done in Italy, as our country is home to some of the best carbon fiber manufacturers. These companies, due to their proven technical and manufacturing skills, count among their clients brands like Ferrari and Ducati.

For each Formigli model, the tubes are personally designed by Renzo and made entirely in-house. We begin by laying up the carbon fiber — multiple layers, oriented and applied by hand inside each tube — shaping the precise profiles required for that model and its intended performance. The first step in frame construction is, without a doubt, the design, which outlines the shape to be achieved, constantly checking its faithful adherence to the original idea through a 3D model.

Next, with the consultation of a carbon fiber technician, the profile and performance of each tube are carefully examined to decide which variant of the material is most appropriate for its use. With this system, after testing tubes of various shapes and combining them with different carbon fiber fabrics, we have managed to achieve high torsional rigidity across the entire range.

To configure a frame that is strictly “custom-made,” specific and precise information about the cyclist’s style and physicality is needed to ensure a unique and fully personalized bicycle. However, the verification of the customer’s measurements is crucial to best configure the performance and actual handling of the bike.

After the design, the real manual work begins: each tube we create is machined, then laid into its mask and custom-cut for the individual rider before being fitted onto the construction jig. Following the pre-assembly of the frame through a sealed bonding process, the vacuum carbon layering process begins — a method that allows us to create a much stronger frame compared to other procedures. Here, we apply the carbon by hand, shaping every junction layer by layer to achieve the precise performance we designed. Finally, the joints are meticulously sanded and hand-finished.

These processes are the essential characteristics of Formigli products, which require particular care and great precision. The tube-by-tube construction process guarantees a perfectly customizable frame and allows the use of any type of carbon fiber, depending on the intended use and the bike’s configuration.

Once the work is completed, graphics and colors are developed in collaboration with the client, who can rely on our painting expertise, where each frame is individually followed from start to finish, ensuring that we deliver a truly unique product to our client.

Steel

In recent years, advancements in bicycle construction have led to remarkable results, thanks to the adoption of increasingly innovative materials. However, even today, some of the qualities of the steel remain unrivaled. It is no coincidence that, with the advent of new steel alloys, we have managed to achieve enviable characteristics even through the use of other materials. The evolution of this material has ensured extremely high-performance bicycles, without compromising their best quality, namely the comfort of riding, which significantly reduces vibrations caused by a road surface that is often imperfect.

Steel is still a classic that is still in high demand today: Gimondi, Merckx, Anquetil, Bobet have won important races while riding “steel machines”. Cycling enthusiasts will say that “nothing can compare to this noble material”, which exemplifies a tradition, craftsmanship, and a perfection tested over time.

No one is willing to give up distinctive elements of a handmade Italian product, which represents a symbol in the history of bicycles in our country. We at Formigli are aware of this, and that is why, by learning and making the most of the construction techniques of the past, we made the decision of investing in research and design processes to build the “perfect” frame that meets the needs of an increasingly demanding and professional audience. Excellence is achieved thanks to the experience gained thanks to the work of the best Italian masters in the field, and also by making the most of the secrets of the frame-building art, we are aware of the importance of the “one-of-a-kind” piece. So it is no coincidence that we choose to produce individually each piece taking care of every steel frame, without being seduced by the numbers that mass production generates, but focusing instead on the quality of our product so we can make sure that we establish and maintain a special bond of trust between manufacturer and customer.