Blackstone Studio

1. Finding the Right Carbon Scrap

The journey begins with a simple, hard‑earned lesson: not every “recycled” fiber is created equal. Early on we bought cheap off‑cuts from a local aerospace shop and ended up with delaminated tubes that cracked on the first climb. Today we partner with three vetted suppliers who provide certified, high‑modulus reclaimed carbon that meets aerospace‑grade tensile standards.

• Supplier vetting – Each partner must supply batch‑level test reports (ASTM D3039) and a traceable chain‑of‑custody from the original aircraft or wind‑turbine blade. We keep a digital ledger of every lot, so a rider can ask, “What was this frame made from?” and we can point to the exact source.
• Material sorting – Upon arrival, the carbon sheets are laid on a light table. Technicians separate clean, undamaged plies from those showing resin bleed‑through, heat discoloration, or micro‑cracks. Only the pristine layers go into our frame‑building line; the rest is shredded for re‑infusion into composite flooring for the studio.

2. Choosing a Biodegradable Resin

A few years ago we experimented with a fast‑curing epoxy that promised low VOCs but left a sticky, brittle finish. The lesson was clear: biodegradability must not sacrifice performance. Our current formulation is a plant‑based, bio‑epoxy (derived from lignin and bio‑propylene glycol) that meets the same shear strength as conventional epoxy while fully breaking down in industrial composting after 12‑18 months.

• Performance testing – We run the same ASTM D790 flexural tests on coupons cured with the bio‑resin. Results consistently show a 5‑7 % higher modulus than the baseline polymer, thanks to a nano‑silica reinforcement that is also plant‑sourced.
• Safety & handling – The resin is low‑odor, BPA‑free, and non‑flammable. Our workshop uses a closed‑loop mist extraction system that captures any volatile particles, ensuring a clean‑air environment for the artisans.

3. Low‑Waste, High‑Precision Workflow

The real magic happens when reclaimed carbon and bio‑resin meet a lean, low‑waste assembly line. Each step is designed to eliminate scrap before it is created.

| Step | What We Do | Waste Reduction Technique |
|------|------------|---------------------------|
| Design Transfer | CAD models are exported to CNC‑cut templates that guide tube cutting. | Zero‑cut‑off: CNC cuts to exact length, eliminating the need for trimming.
| Lay‑up | Hand‑lay carbon plies, then infuse bio‑resin using a vacuum bag. | Closed‑system infusion: All excess resin is collected and re‑filtered for the next lay‑up.
| Curing | Frames cure in a solar‑assisted oven at 60 °C. | Heat recovery: Exhaust heat pre‑warms incoming air, cutting energy use by 30 %.
| Finishing | CNC‑milled joints, polished with reclaimed sandpaper, then hand‑painted with low‑VOC pigments. | Reclaimed abrasives: Sandpaper is reclaimed from previous jobs, sanded and re‑coated.
| Quality Control | Ultrasonic testing and fatigue cycling. | Digital documentation: Defect data feeds back into the design loop to reduce future re‑work.

The result is a frame that is 20 % lighter than a comparable all‑new carbon build while generating less than 0.2 kg of waste per bike – a figure we publish on every spec sheet.

4. The Hard‑Learned Payoff

Clients often ask, “Is the extra effort worth it?” The answer is threefold:

1. Longevity – Reclaimed carbon retains its original high‑modulus properties, so the frames last as long as new‑material equivalents.
2. Transparency – Our digital material ledger gives buyers a carbon‑footprint badge they can display proudly.
3. Planetary Impact – By diverting 1 ton of composite waste from landfill each year, we offset roughly 30 % of the emissions from a typical mid‑size bike production run.

When you choose a Blackstone Studio frame, you’re not just buying a bike; you’re adopting a story of redemption – from discarded aerospace parts to a bespoke performance masterpiece – built with the same discipline a seasoned rider learns on the road: measure twice, waste never.