Bridge Bike Works isn’t just any bicycle startup. Rather than design something and outsource the engineering, manufacturing, painting, and assembly, they opted to create all of that capacity in-house, in a brand new factory. Based in Toronto, Canada, BRIDGE has been quietly building, testing, and iterating on the design for their first model, the Surveyor
Bridge Bike Works isn’t just any bicycle startup. Rather than design something and outsource the engineering, manufacturing, painting, and assembly, they opted to create all of that capacity in-house, in a brand new factory.
It’s also climate controlled, so they pull the carbon rolls in here overnight to soften to the right level for cutting the next morning. If it gets too warm and tacky, it can’t really be cut or assembled properly, so this lets them stage it. Not only could this let them offer custom geometry in the future, it makes it really easy for them to tweak the designs and test new shapes and layups during development. It’s also much faster and cheaper than outsourcing it or making them out of metal.
Once prepped, the tubes and joints are placed inside the molds and air tubes are run to inflate a bladder and press the carbon outward, which is essential for comparing the carbon to shape it and effectively make all the layers one piece. Bridge is even making their own forks for the Surveyor, which they’ll also offer to other frame builders.The parts are impressively smooth inside and out. The design of the parts lets all of the tubes be sleeved together, then bonded and overwrapped to connect them.
Once all the parts are made, they’re put into this Benchmark framebuilding jig for assembly. These jigs dial in all of the necessary geometry details for each size. Bridge has also created custom parts to index each critical tube to ensure perfect alignment at every step. Once the complete frame comes out of the oven and has finished cooling and curing, the now completely functional frame needs to be prepped for paint. The overwraps are filled with top-end aerospace grade filler and sanded smooth before going into the paint booth.
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