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Fisher Price, we need to talk!
by Ann-Kathrin Schäfer
Carbon dreams come true: taking a look at the production of bikes «Made in Switzerland»
3.7.2024
Translation: Jessica Johnson-Ferguson
Pictures: Manuel Wenk
Almost all bikes made of carbon are imported from Asia. Not so the bikes from Nostra. A small carbon forge develops and produces frames entirely in Switzerland. We got to take a closer look at this unique, highly complex craft.
The hills around Einsiedeln are shrouded in a thick blanket of cloud. It’s cold and rainy. At the end of the village stands a small industrial building with a large window front. The lights are on and there are people bustling about inside. I go through the doors of what used to be the canteen of a large electronics manufacturer and find myself in a different, fascinating world – the world of Brasch Design Composites.
There are carbon works-in progress everywhere I look. Company founder Roman Braschler’s customers include private individuals with special requests such as a carbon camping kitchen. Then there are industrial customers including the Swiss Bobsleigh Association and companies that require robotic arms for the production of pet bottles.
Recently, bikers have also joined their customer base. Together with Gamux Bikes, a company based in Wangen, central Switzerland, which is in charge of the kinematics, Roman and his team have brought a carbon bike «Made in Switzerland» to market maturity. «It’s a dream bike,» Roman Braschler and long-time-employee and co-developer Swen Kälin tell me.
Once all pre-cut prepregs have been placed in the aluminium mould, the two halves are joined together and sealed. The air’s pumped out and the aluminium block’s heated to over 110 degrees Celsius – the exact temperature remains a secret. This makes the resin liquify and the carbon fibres stick together.
Painting is also carried out in-house and can be done according to customer requirements. Nevertheless, Swen recommends a standard paint finish: «Most customers are overwhelmed by the endless possibilities. So it’s easier to opt for our standard paint finish.» It takes over 50 working hours to insert the carbon fibres into the moulds, cure and paint them, and finally assemble them.
The complete frame with rear triangle, linkage and titanium bolts weighs a slender 2,200 grammes. And yet, there are lighter bikes on the market. Instead, Roman and his team have paid particular attention to durability and robustness. Their aim is to ensure that any falls and crashes are better absorbed. At the same time, this should allow professional riders to only reach their own limits, not those of the equipment.
In the meantime, the weather in Einsiedeln has improved. The clouds have slowly given way to the sun. Roman, Swen and Manon, all keen bikers, want to go for a spin on their bikes in the evening. On a Nostra, of course.
Header image: Manuel Wenk
Manuel Wenk
Communications Manager
Manuel.Wenk@digitecgalaxus.chAs a Multimedia Producer, preparing multimedia content and knowing about cutting-edge technology is my business. My main focus at digitec is producing videos. I can’t wait to try out new products such as cameras, drones or smartphones as soon as they’re launched. This is where being at the source comes in rather handy. When I’m not working, I’m probably skiing, biking or hiking – the mountains are my place to be.
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