Traditional carbon fiber handlebar manufacturing relies on multi-stage mold assembly, resulting in low production efficiency and structural weaknesses at the joints. The new one-piece molding mold uses a detachable inner module system to achieve the overall molding of complex curved handlebar structures: the upper and lower molds are combined to form the handlebar cavity, and the first inner module dynamically constructs the upper and lower curved handlebar surfaces, improving demolding efficiency by 40%. This design solves the problem of interlaminar stress caused by the separate manufacturing of carbon fiber curved surfaces. The product has passed the ISO 4210 safety standard test, and its torsional stiffness has increased by 22%.

Fluid melting technology achieves hollow functional structure
The latest 2025 process will combine thermoplastic engineering plastics with unidirectional carbon fiber reinforcement:

1. Fluid melt injection molding : High-pressure nitrogen is injected into the mold to form a hollow thin wall, increasing material utilization by 25% and shortening the single-piece production cycle to 1 minute;

2. Fiber directional reinforcement : Four sets of unidirectional carbon fiber tapes are implanted in the mold, and the bending strength of the key stressed areas reaches the aviation standard, reducing the weight by 30% compared to aluminum alloy;

3. Functional integrated design : Embedded cable channels and lighting units avoid external wiring wind resistance.

Sustainability breakthroughs and mass production prospects
The new process uses a closed-loop recycling system, and the thermoplastic matrix material can be repeatedly melted and reused. Combined with the European localized production system, the life-cycle carbon footprint is reduced by 70% compared to the metal solution. The first batch of mass-produced products will be launched in the fall of 2025, and the prototype components in the engineering verification phase have passed extreme temperature cycles from -30℃ to 85℃ and 200G vibration tests. The potential for technological extension is significant, and it may be applied to complex structural parts such as frames in the future.