Speaking in a similar manner as we use to talk about our other bike frames, the Express takes shape in a monocoque construction. The Express’s frame is manufactured via a process known as EPS (expanded polystyrene) molding. This process creates an inner mold that expands under heat to apply pressure to the prepreg carbon to have the carbon exactly match the shape of the outer mold. This creates a tighter compaction of the prepreg carbon layers, ultimately leaving us with a frame that is free of any cavities or irregularities. Eliminating any variance is the key to strength and durability within a composite frame. We have engineered strength in reinforced areas around the drive unit mount and other critical junctions within the frame to handle the torque output from the drive unit and the robustness needed for components like the battery. With that being said, the dropped seatstays, longer exposed seat post, and directional layup (reinforced where needed and reduced where comfort can be added) were all design decisions made early on to create comfort for the rider. Our geometry and components spec on this frame was selected to give the rider an upright riding position that would be more sustainable for extended rides while also allowing greater control of the bike. By designing the Express’s frame out of a composite material, we were to create stiffness and alignment where needed while ensuring that the layup and design prioritize the rider’s comfort.