We don’t simply work with carbon fibre. We design its behaviour.
A frame is a balance before it is a shape.
Zecchetto Group technological pillars
Performance, layer by layer.
The pre-impregnated carbon fibre sheets combine selected fibres and epoxy resins, arranged according to specific lamination sequences to control stiffness and strength. There is therefore no single type of carbon: fibre, orientation and lay-up are chosen to achieve the desired result: a frame that is rigid under power, precise through changes of direction and controllable even in the most demanding conditions, without compromising on lightness, balance or reliability.
Lightness is a value. Engineered lightness is technology.
Structural continuity. Energy without loss.
When the design calls for a monocoque construction, the carbon fibre sheets are laminated within a dedicated mould to create a continuous, coherent structure.
The continuity of the fibres allows stresses to be distributed along the frame, reducing structural discontinuities and optimising the balance between stiffness, strength and weight.
The result is a platform capable of responding instantly to pedal input and maintaining precision and stability under load.
A more uniform structure, a more direct response, a profoundly natural riding experience.
The machine repeats. The person interprets.
At Zecchetto Group, automation and craftsmanship are not two opposing worlds.
Technology guarantees precision, control and repeatability. Human expertise comes into play where sensitivity, adaptability and experience with the material are required.
A plotter can cut with absolute precision. A technician knows how to recognise the behaviour of a carbon fibre skin. A robot can repeat a process thousands of times. An expert hand can detect an imperceptible variation and intervene before it becomes a flaw.
We use automation where rigour is required; we leave what calls for judgement to people.
From carbon fibre to the road.
1. Mould design and construction
This is where performance takes shape.
The mould translates the digital design into a physical form. It must ensure dimensional accuracy, stability throughout the thermal cycle and repeatability over time.
Direct management of the moulds allows us to control tolerances, development times and surface quality, as well as speeding up the refinement of each new project.
Before shaping the carbon fibre, we build the exact space in which it will become a structure.
2. Controlled storage
Protecting the material’s potential.
The pre-impregnated carbon fibre sheets are stored in temperature-controlled cold stores.
Temperature control slows down the resin’s reaction and allows the material to retain its workability, stability and mechanical properties until it is used.
The quality of a frame begins before the fibre enters the mould. It begins with the way it is stored.
3. Precision cutting
Digital technology. The human touch.
Nesting software organises the shapes to be cut, optimising the layout of the sheets and reducing material waste.
Automatic plotters ensure speed, precision and repeatability, whilst respecting the fibre orientation specified in the design.
4. Lamination in a controlled environment
This is where the character of the frame is forged.
Lamination takes place in environments where temperature, humidity and dust concentration are controlled.
Following a defined sequence, technicians manually position each carbon fibre element within the mould. The orientation, overlap and continuity of the fibres determine the mechanical behaviour of the various areas of the frame.
In this stage, the team decides how the frame will transfer power, respond to stresses and interact with the cyclist.
5. Vacuum and autoclave
Pressure, temperature, time.
Once the lamination is complete, the mould is closed and prepared for the vacuum process. This process ensures the layers bond correctly and helps to remove any residual air from the laminate.
The component is then subjected to a controlled temperature and pressure cycle in an autoclave.
Each parameter is defined according to the component and the materials used.
This is the moment when the design becomes a structure.
6. Surface preparation
Perfection begins with what you cannot see.
Before being painted, each frame undergoes a series of processes dedicated to surface preparation.
Sanding and inspections are repeated until a uniform, smooth base is achieved, ready for the final finish.
It is a labour of patience, where method meets the craftsman’s sensitivity.
Because a perfect finish can only result from a surface prepared with the same care with which the frame was made.
7. Painting and finishing
Technology becomes identity.
The visual identity of Ducati Cycling takes shape on the prepared surface.
Colour, graphics and finish are applied through a process designed to strike the right balance between aesthetic quality and weight reduction.
The graphic lines interact with the frame’s geometry. The colour emphasises its shape, movement and personality, transforming a high-performance structure into an instantly recognisable object.
The paintwork does not hide the technology; it reveals it.
8. Quality control
Quality is not the final stage; it is an integral part of the entire production process.
Materials, lamination, surfaces, dimensions and interfaces are checked at various stages of production. The finished component undergoes visual and dimensional checks, fit tests and functional checks.
Every detail must meet the established parameters before moving on to the next stage.
9. Final assembly
The frame becomes a bicycle.
Once the paintwork is complete, the frame is fitted with the required components.
The drivetrain, braking system, wheels and other components are fitted and adjusted according to defined procedures.
Particular attention is paid to fit, alignment, tightening torques and ensuring every system works correctly.
Assembly requires precision, technical expertise and attention to every interface. Tightening torques, couplings and adjustments are carried out with care to ensure functionality, reliability and consistency with expected performance levels.
At this stage, the frame is fitted with all the necessary elements to form a complete bicycle, and is ready for final checks.
All the technology you can’t see. All the sensations you feel.
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