The All-Terrain Touring Bike is engineered for unsupported expedition touring, gravel bikepacking, and heavy-load utility transport across variable surfaces. Built around a triple-butted structural frame and robust geometry, this platform balances high torsional rigidity under cargo with vertical compliance for long-distance rider endurance. Configured for high-volume brand distribution and fleet deployment, the frame integrates 34 mounting points for racks, fenders, and fork cargo cages. Production utilizes automated robotic TIG welding paired with manual root pass inspection, ensuring consistent joint integrity for high-stress expedition environments.
Key Product Features
Structural Frame Architecture: Constructed from hydroformed AL6061-T6 aluminum or custom-drawn chromoly steel, featuring a reinforced headtube junction and dropouts rated for a 160 kg maximum system weight.
Expedition Cargo Capacity: Integrated stainless steel threaded bosses on the fork blades, downtube underside, and seatstays support direct-mount low-rider racks and multi-liter cargo cages without frame clamps.
Maximized Tire Clearance: Accommodates up to 29x2.35-inch or 27.5x2.8-inch wheel configurations, allowing riders to transition from paved tarmac to loose gravel and singletrack without frame rub.
Standardized Thru-Axle Interface: Utilizes 12x142 mm rear and 12x125/148 mm front thru-axles with replaceable stainless steel derailleur hangers to eliminate frame flex and maintain rotor alignment under heavy loads.
Internal Cable Routing: Full-length external cable guides alongside internal routing options protect shift and brake lines from dirt ingress while simplifying field maintenance in remote locations.
Technical Specifications
|
Parameter |
Specification |
|
Frame Material |
AL6061-T6 Heat-Treated Aluminum / Reynolds 520 Chromoly Steel (Custom Option) |
|
Fork |
Carbon Monocoque or Chromoly Steel with Triple-Boss Cargo Mounts |
|
Sizes Available |
S, M, L, XL (Custom geometry available on request) |
|
Max System Load |
160 kg (Rider + Luggage + Bike) |
|
Bottom Bracket |
Threaded BSA 73 mm (Standardized for global field serviceability) |
|
Seatpost Diameter |
27.2 mm (Optimized for micro-suspension seatpost compatibility) |
|
Brake Standard |
Flat Mount / Post Mount Disc (160 mm / 180 mm rotor compatible) |
|
Headset |
Tapered 1-1/8" to 1-1/2" Integrated Sealed Bearing |
|
Safety Standard |
ISO 4210-2 (Trekking / Mountain Bicycle Standard) |
Applications
Commercial Adventure Fleets: Deployed by guided tour operators requiring durable frames that withstand unpaved multi-day expedition routes.
Bikepacking & Outdoor Brands: Supplied as complete builds or frame sets for brands expanding into adventure cycling and touring categories.
Municipal & Utility Transport: Utilized by couriers and last-mile delivery services needing high cargo capacity and puncture-resistant multi-surface capability.
Manufacturing & Quality Control
Production operates out of a 25,000-square-meter facility equipped with Trumpf fiber laser cutting machines, CNC tube-bending centers, and OTC robotic welding cells.
Dimensional Accuracy:
Laser alignment benches verify frame triangle tolerances within +/-0.5 mm before heat treatment.
Weld Integrity Testing:
100% of critical headtube and bottom bracket weld clusters undergo visual inspection, supplemented by periodic destructive tensile testing and X-ray flaw detection on sample batches.
Surface Treatment:
Frames undergo an automated 7-stage chemical wash, zinc-phosphate anti-corrosion primer dip, and electrostatic powder coating cured at 200°C, achieving a salt-spray resistance rating exceeding 500 hours (ASTM B117).
Fatigue Testing:
Frame prototypes undergo ISO 4210 vertical drop, horizontal impact, and pedal force fatigue testing cycles (exceeding 100,000 revolutions) prior to mass production release.
OEM / ODM Customization
Geometry Adjustment: Modification of stack, reach, chainstay length, and head tube angle to match specific regional fit requirements or brand riding philosophies.
Mount Integration: Custom placement or addition of braze-ons, cable stops, internal dynamo routing ports, and belt-drive split dropouts (e.g., Gates Carbon Drive compatibility).
Branding & Finish: Custom Pantone color-matching, wet paint or powder coat finishes, laser-etched seatstay bridges, and water-transfer or metal headbadge placement.
Component Kitting: Pre-selected build kits sourced directly from Shimano, SRAM, TRP, and WTB based on target price points and tier positioning.
Packaging
Individual frames or complete semi-knocked-down (SKD) bikes packed in 7-layer double-wall corrugated cardboard boxes (BC-flute).
High-density EPE foam blocks secure vulnerable zones including dropouts, headtubes, fork tips, and handlebar assemblies to prevent transit abrasion.
SKD units or frame sets organized on ISPM 15 heat-treated wooden pallets, shrink-wrapped, and edge-protected for containerized sea freight.
Request a Quote
Submit technical drawings, target volume, and specification requirements to receive a formal quotation and sample lead time within 24 hours.
[ Request a Quote / Submit Specifications ]
FAQ
Q: What is the minimum order quantity (MOQ) for custom frame geometry and paint colors?
A: The standard MOQ for custom frame geometry and private-label paint finishes is 50 units per size/colorway. For off-the-shelf catalog frames with standard branding, the starting MOQ is 20 units.
Q: What documentation and test reports are provided with production batches?
A: Each shipment includes material mill certificates for the aluminum or steel alloy used, dimensional inspection reports, and third-party ISO 4210 laboratory test certificates upon request.
Q: Can the frame be configured for both belt drive systems and traditional derailleurs?
A: Yes. The dropout junction can be engineered with a structural split-stay interface to accommodate Gates Carbon Drive systems, alongside standard derailleur hanger options for conventional 1x or 2x drivetrains.
Q: What is the standard lead time for sampling and mass production?
A: Rapid prototyping and geometric sampling take 35 to 45 days. Standard mass production orders of 100 to 500 units are completed within 55 to 65 days from final artwork and specification sign-off.
Q: How do you prevent corrosion on steel touring frames during ocean freight?
A: Chromoly steel frames receive an internal anti-rust ED (electrodeposition) coating applied prior to exterior powder coating, sealing internal tube chambers against moisture during maritime transport.
Q: What warranty terms apply to OEM/ODM frame manufacturing defects?
A: Frames carry a 5-year structural manufacturing warranty covering weld failure, material cracking, and structural misalignment under normal operating conditions within the specified maximum load limits.
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