Carbotronics Power Frame News All the technical details you need to know
The e-bike industrial revolution is born from forged carbon
From the Motor Valley to the future of lightweight mobility: Carbotronics presents Power Frame, the first forged carbon monocoque frame that fully integrates the power unit. A new product, and at the same time a new industrial standard for electric micromobility.
Designing and producing a power unit for micromobility is a complex engineering challenge, which requires the perfect integration of sensors, software, electronics and mechanics. The heart of the project is the user experience: silent, vibration-free, pedaling similar to natural pedaling. With Zero Drag technology, patented by Carbotronics, the electric transmission disengages completely above 25 km/h, offering unprecedented fluidity.
European industrialization and intelligent reshoring The CF-SMC forged carbon frame is produced in Europe with a highly automated process (less than 20 minutes for a complete frame). This approach allows for reduced development times, scalable production, consistent quality, and costs comparable to current Asian ones.
From prototyping to production, Carbotronics has developed all the skills internally: design, mold construction, assembly. Thanks to an entirely European supply chain, the system is already ready for large-scale production and can be applied in other sectors where aesthetics, lightness, robustness and integration are key factors.
Carbotronics will present Power Frame at Eurobike 2025 (Frankfurt, June 25-29) at Stand F12 I05.
TECHNICAL DETAILS – POWER FRAME
1. The Power Unit concept
The Power Unit developed by Carbotronics represents an advanced mechatronic system, which perfectly integrates sensors, electronics, control software and mechanics. The goal is a natural, non-invasive assistance, which is activated only when necessary. The system is designed to ensure:
Silent and vibration-free operation
Immediate and synchronized feedback with the user
Precision in sensor management and software control
2. Patented Zero Drag technology
The transmission adopts a proprietary technology with a free wheel set that allows:
Zero engine resistance above 25 km/h and when disconnected
Maximum mechanical efficiency
Reduction of energy losses and greater battery autonomy
3. Electronic integration and communication
100 Nm 48V motor with current optimization to limit heat
Self-supporting control board, installed directly on the motor
Absolute position sensor integrated into the PCB
CAN bus communication with diagnostics on proprietary software (LabVIEW)
Integration with user display and Bluetooth app for monitoring and setting parameters
Compatibility with different formats and battery capacities
4. CF-SMC carbon structure
Isotropic composite material already used in racing cars
Highly industrialized process with cycle times of less than 20 minutes
Structural integration of mechanics and electronics without bolts
Lightweight, rigid and machineable
Engine casing and frame made of CF-SMC in complex geometry molds
Optimization of heat dissipation through inserts and engine design
5. The Power Frame: the first integrated monolithic frame
Frame and traction system designed as a single entity
Optimized and patented production process
Challenge won: deep cavities and monoblock structure in CF-SMC
Final product: silent (<60 dB), powerful (up to 5000 rpm), ready for scalability
Power Frame is therefore not only a project for e-bikes, but also a technological platform ready to redefine the standards of micromobility and offer transversal solutions to sectors with high technical complexity.
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