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In 1973, the Rossignol Ski Corporation employed our company's engineers to manage their Tennis Racquet Division in Van Buren, Maine. Over the next decade, our team perfected the fine art of producing complex composite structures. Tennis legend, Mats Wilander, won many tournaments using racquets developed and manufactured in our Van Buren plant. Unfortunately, cheap Taiwanese labor challenged Made-in-USA profitability, and our engineers were forced to seek a more complex, less mass produced item; the bicycle.

Initially, our team was contracted by Trek to produce carbon fiber tubing (pre-OCLV) for their model 2500. The Trek 2500 was manufactured by bonding carbon fiber tubing to aluminum lugs. Even though the 2500 was a huge success and marked a key turning point in the bicycle industry, it still employed traditional construction processes - lugging. By joining carbon fiber tubing to aluminum lugs, we felt carbon's greatest inherent quality, shock absorption, was lost. While super-strong and light weight, these models suffered from a rough ride. Once again, improving on a good idea, our team set out to produceall carbon monocoque (one piece) frame in order to take full advantage of carbon fiber's shock absorption and strength qualities.In 1986, our team manufactured the first monocoque bicycle frame manufactured in the USA. Confident with our technology, Trek, a traditional steel and aluminum manufacturer, strongly supported the project. As a result, the Trek model 5000 (also pre-OCLV) was introduced, the world's first mass production carbon fiber monocoque. Fortunately, for a variety of reasons, this relationship with Trek ended shortly thereafter. However, convinced of the viability of carbon fiber for the cycling industry, our engineering team joined with several former Trek employees to file patents for the construction of bicycle frames utilizing our revolutionary bladder-molding process, a superior construction method for the molding of composite structures. Yet, the group did not quite agree on the benefits of a full one piece versus a three piece design.

Specifically, we believe that in molding a one piece frame, three critical aspects are at risk:

continuous, consistent compaction
stable structural integrity
exact frame alignment

Ironically, a one-piece design requires two different construction processes. Due to the immense complexity of the structure being formed, it is virtually impossible to thread a bicycle frame entirely with bladders. This is demonstrated with the fact that a single inflated bladder running through the down tube will not "split" into the two chain stays. The result- loss of compaction. Therefore, a one piece design necessitates both the bladder molding (front) and foam core injection (read end) methods.

Consequently, due to assorted manufacturing techniques employed during the construction process, a product's end result can vary significantly. Most notably, structural inconsistencies arise, particularly in high stress areas such as the bottom bracket and seat tube/seat stay areas. Another observed problem with the one piece design was an inability to accurately control frame alignment and durability. This was because the one piece construction technique incorporates a "clamshell" of lay-up, where a "left" half of the frame is bonded to the other "right" half during the molding process. Two things can happen here... 1) Misalignment of the two halves requires extensive post production machining and alteration of the dropout hangers to compensate for frame misalignment. 2) The two frame halves are inevitably held together by a resin seam, thus creating an inherent seam line around the periphery of the frame. We believe a seam line of such proportion jeopardizes the structural integrity throughout the entire frame.

Not wanting to compromise the performance and durability of a great frame, our founders sought an entirely different approach to the construction design- the three piece, non-full monocoque approach. With strongly opposed manufacturing philosophies, we parted ways with members intent on producing frames utilizing the monocoque/one piece construction technique. While the "other half" went West to establish Cycle Composites d/b/a Kestrel, we, here in Maine, applied for and were awarded another new patent for forming our frames utilizing our new, revolutionary three-piece concept. Our sole intention was to produce a perfectly aligned frame that was consistent throughout in terms of raw material content, compaction ratio, and overall structural integrity. This would be achieved by forming all parts of the frame through invariably constant construction methods. As a result, Aegis frames would be seamless tubes of continuous fibers that were identical in regards to pattern and procedure for carbon lay up, molding systems, and compaction method. This strategic approach would guarantee undeviating frame performance, longevity (durability), and precision alignment. This was all accomplished with our three piece design.

Using this design approach, we accomplished consistent, uniform part performance by bladder molding of all three frame components - front triangle, seat stay and chain stay under the same process. Furthermore, for fear of weak seam lines, these parts were not laid up in halves, but rather as a whole. Essentially, the pieces begin and end with the very same fibers spiraling throughout (yet still not filament wound). From end to end, these fibers are oriented in such patterns so as to eliminate any seam line, thus maximizing durability. These three separate, yet congruous, parts are then fused together within a frame alignment jig; hence superior frame alignment.

To that end, we had produced the world's finest composite frame.

Employing our new methods, we founded Graphite Technologies, and began producing for the likes of Basso, Profile, Peugeot, Iron Horse, and Racing Bik. Once again, these "captive" relationships proved to be unfavorable for our company, and forced us to re-think company objectives. In 1993, with the introduction of the Aegis line, we happily committed ourselves to exclusively produce and market our own products.

Today, Aegis remains a proud Maine company of truly skilled and dedicated craftspeople. As always, we are devoted to providing our customers with the very finest bicycles. Our rich history with advanced materials and patented, race-proven technology combined with our Maine-Made craftsmanship yield bicycles of exceptional quality, performance, durability, and value. Every Aegis features top shelf, aerospace grade materials, proprietary monocoque construction, and sterling craftsmanship- all keeping our bicycles at the pinnacle of high performance. Moreover, we offer the world's largest range of carbon fiber bicycles - road, mountain, triathlon, cross, compact, and track- as well as many custom options. Finally, all our products feature the finest commitments to our customers- a lifetime guarantee and lifetime crash replacement program. While our pioneering spirit endures for another generation, our venture of innovation of perseverance will be expressed with great bicycles.

Aegis continues to produce the most comfortable and fastest carbon frames. Even though most traditional metal frame companies have tried to mimic our techniques, their focus is on weight and not ride quality. While we are always experimenting with new carbon and new layups, we will not sacrifice the reason why we believe riding a carbon fiber bike is so great.. the ride.

The metal manufacturers also have made a strategic decision to produce their U.S., Canadian, Italian, etc. in Asia. We believe, at AEGIS, that Made in Maine, USA still matters.

Pete Orne, Owner