Our manufacturing process from 3D laser fusing to final painting requires over 130 hours of precision work by machine and more than 70 hours of meticulous hand craftsmanship.
We believe every rider should be certain their bike is safe and that every frame that leaves our workshop should last a lifetime. That’s why Bastion frames are certified to international standard ISO 4210. We are among the few custom builders in the world to do this, and we pride ourselves on our integrity. A Bastion bike is always delivered to the promised standard with the technical reports to prove it.
Our lugs are formed out of aerospace grade Titanium alloy powder. A specialised laser then fuses the powder to your exact specifications in a hermetically sealed, inert gas environment. The result is mechanical properties that rival those of forged parts.
Our tube sections are wound layer by layer in carbon fibre over a mandrel in a computer controlled process called filament winding. This enables precise fibre orientation and continuous fibre paths giving us ultimate control of the performance characteristics of your bike.
By combining Titanium and Carbon Fibre, Bastion bike frame technology gives you the best of both worlds, to create the best frame in the world. Our engineers have fine-tuned the ideal combination of Titanium and Carbon Fibre to yield a frame with the optimum balance of performance and mass. It’s the rider’s holy grail – a frame that blends the torsional stiffness and performance of a Carbon Fibre frame with the ride comfort of a Titanium frame.
The frame’s tube sections, which are the areas of highest deflection, use Carbon Fibre because of its renowned damping properties. However, in areas such as the bottom bracket, carbon fibre creates an overly stiff joint that compromises ride comfort. Here we use Titanium. Only the finest grade Ti6Al4V Titanium Alloy is used and the latest 3D printing technology allows us to form it into previously impossible shapes to create Bastion’s breakthrough frame design. We utilise the lower stiffness of Titanium to better isolate the high frequency vibrations of rough roads, whilst maximising torsional stiffness through asymmetric structures, transforming both ride and performance.
Throughout the production process you will be given updates through the portal allowing you to track the progress of your build. Upon completion we will issue you with your final invoice before shipping you the bike.