The Alchemy between Vision and Matter

Phase 1: Listening to the Movement

The journey begins with you. We don’t just measure, we interpret your posture and riding style. Through our web app and/or a conversation with your trusted bike fitter, we translate ergonomics into mathematical coordinates. The result is a technical board that is, in effect, an engineering portrait of your performance: angles and lengths that represent your uniqueness.

Phase 2: The Dream Takes Form

From coordinates, we move on to parametric CAD. This is where the first magic happens: the lines of our VERA adapt, maintaining their functionality and aesthetics while accommodating your specific measurements. And certain portions of the mold are automatically adjusted to the frame. Anyone who has delved into our images and patents has already understood part of the method: we work with a unique mold, breakable into multiple parts and adjustable like a traditional jig. The mold is primarily made of aluminum alloy, with more than 90% of the portions we define as “fixed,” while the remaining portions are so-called “variable,” generated each time with a rapid and sustainable process.

From the patent to the final product, several years of development have passed, leading us to improve and optimize numerous aspects of the process and the mold: from the choice of break-down zones to ensuring fast and error-free assembly, from identifying sustainable materials with the right cost/performance ratio for the production of the variables to developing these variables to optimize production times and costs. All these detailed aspects go far beyond the simple patent and are the fruit of years of research, trial and error, reworking, and so on. This explains the reason for such secrecy in the release of photographs of our mold: it is strategic know-how developed with commitment and dedication, which we must keep hidden from prying eyes.

Once the variables have been generated, the mold is quickly adapted and the approximately 300 prepreg shapes that make up the frame are cut using the plotter. For VERA AR, these are made from two types of material:

– a 5HS fabric with T1100 fiber: this is a Toray intermediate modulus fiber used in aerospace and F1 for structural components. The term “intermediate” should not mislead; this class of fiber is among the most valuable, offering the best synergy between stiffness and mechanical strength (two different aspects, both fundamental). The code 5HS stands for 5-End Harness Satin and indicates that a weft thread passes over four warp threads and under the fifth, or vice versa, in a non-consecutive fashion, creating a gap of four strands between the successive crossings and a highly interesting aesthetic and technical result;

– a unidirectional M46J fiber, a so-called “high modulus” fiber, also from Toray, which adds all the necessary stiffness, i.e. the frame’s ability to not disperse energy by deforming under pedaling loads.

The pre-impregnated carbon skins, shaped with surgical precision, are now ready to be placed in the heart of the mold.

Phase 3: The Layering of the Soul

This is the most intimate and complex phase. Our expert hands position each individual carbon “skin” inside the mold. It’s a mosaic of fibers where the orientation of each layer is carefully designed to give the frame the necessary stiffness while maximizing every gram of material. You need to follow the plybook to the letter to arrange each ply exactly where it is supposed to work: nothing is left to chance, every single fibre is located exactly where it is needed to respond to the stresses of an all-out sprint or sudden braking. Once this phase is completed, the internal bags are arranged (with other precautions that every manufacturer guards with great jealousy) and the mold is closed, finally applying the external bag for the vacuum.

Phase 4: The Fire of Perfection

At this point itThe mold is ready to enter the autoclave, the temple of transformation. For 5-6 hours, the combined action of pressure and vacuum extracts every micro-air bubble, while the temperature activates the polymerization process that will harden the resin. It is a slow compaction process that transforms layers of fabric into a single, monolithic body, incredibly light and resistant.

Phase 5: Rebirth and Refinement

Removal from the mold is a rite of passage: the material, still vibrating from the heat of the autoclave, is revealed for the first time in its monolithic, lightweight, and durable entirety. Once free, the frame is entrusted to the meticulous hand finishing process, where eye, touch, and patience become the ultimate measuring tools. Every aesthetic detail is sanded and processing residue removed with surgical precision, until the carbon fiber achieves absolute surface perfection. This meticulous process is applied with the same care to the fork and handlebars, until the entire kit is ready to embrace its final identity.

Phase 6: The Chromatic Soul and the Distinctive Sign

Graphic customization represents the final act of Gregario’s alchemy, the moment when technical structure meets the cyclist’s aesthetic vision. The graphic design isn’t just a simple covering, but an expression of your uniqueness. To give voice to this identity, we offer three creative options:

– Team Gregario Selection: A range of graphic layouts curated in-house to enhance the aerodynamic lines and character of the VERA AR – with colors of your choice.

– Limited Edition: Exclusive projects in collaboration with local artists, capable of transforming carbon into a contemporary art canvas, as in the case of the 2026 version developed with the Truly Design crew.

– DNA Signature: For those who desire a unique personal work, guided by their own personal taste and imagination, a completely personalized and original graphic design, a truly “tailor-made” aesthetic.

Once the signature paint job is complete, your frame kit will be ready for assembly with the best components the market has to offer.