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800 Series OCLV Carbon

How we created 800 Series OCLV Carbon

Necessity is the mother of invention. Like a lot of other big tech developments, 800 Series OCLV Carbon was created to solve a problem—we wanted to make our aero bikes lighter. Aero tube shapes take more material to make, so they are generally heavier than typical tubes. A new, lighter carbon layup would ensure the added weight of aero tubes wouldn’t offset gains in speed.

A game-changing new fiber

800 Series OCLV Carbon contains fibers that are 30% stronger than previous carbon fibers we’ve used, while retaining the same amount of stiffness. That means that we can use less of it than a different type of carbon, and still get the same effect. This is huge—it allows us to make aero shapes without adding a ton of weight.

A dialed process

There are lots of carbon bikes out there, but not all carbon bikes are created equal. Carbon fiber is an incredible yet complicated material to build things from. To do so successfully takes a lot of expertise—something we’ve been cultivating for over 25 years through our OCLV Carbon process.

We’ve learned that the real magic comes in knowing what types of fibers to use, and where to use them. It’s a process our engineers compare to tuning a piano. It’s not just about materials the piano’s made from or having the loudest piano. It’s about creating something that’s more than the sum of its parts—a beautiful sound. Getting a piano to sound stunning (or building a bike that’s a joy to ride) is both a science and an artform.

It’s all about the layup

Because it’s not just about the carbon, it’s about how the carbon is laid up, M40X is only as incredible as we make it. We had to put the right fiber in the right place to give the frame the perfect balance of stiffness and strength. Stiffness is a measurement of the bike’s responsiveness, and strength determines how capable the bike is at absorbing and distributing forces incurred while riding.

Testing 1, 2, 3, 4, 5…

With the help of advanced computer modeling, we developed over 50 layups to find the new 800 Series OCLV. Each prototype had different kinds of carbon placed in different areas depending on the stressors occurring at each part of the frame, and on the qualities we wanted the new frame to have.

We meticulously tested and quantified each laminate’s structural integrity, weight, and ride quality, which was crucial in helping us determine exactly why we liked the performance of one laminate over another. Once we narrowed it down to just a few layups, we had Trek-Segafredo racers test ride the bikes and tell us which frame they liked the best.

Our best carbon ever

It took more than two years of development, but 800 Series OCLV is the lightest and highest-performing carbon layup we’ve ever created. It’s stronger than our previous laminates, yet just as stiff. The advent of 800 Series OCLV marks the start of a new era for our highest-end aero bikes—never again will we have to sacrifice weight for speed.

Émonda SLR

Lightest, fastest, first up every climb—this bike delivers incredible ride quality and aerodynamic advantage. It’s made of all-new 800 Series OCLV Carbon and weighs less than 700 grams.

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