Masters Of The Craft
So often we're asked what's better: carbon, aluminum, Ti, magnesium, steel, bamboo...? Our answer is always the same. It's not the material, it's what's done with it. At Ellsworth, we call this Material Management. Whether we are crafting our U.S. frames or working with our carbon manufacturer on design specifics, we manage each material we use from start to finish. Exploiting the material's unique strengths and eradicating its weaknesses with specific design solutions.
Instant Center Tracking™ (ICT)

Instant Center Tracking™ (ICT)
Internationally patented and quantifiably the most energy-efficient suspension design in the World, ICT tuned four-bar linkage design provides a true zero-energy loss to suspension function. By aligning the instant center on the chain torque line and continually tracking the chain torque throughout the range of travel, ICT is accomplished without the need of a lockout. This keeps the suspension fully active and always on, resulting in increased traction and control, and reduced rider fatigue. ICT suspension is internationally acclaimed and continues to set the bench mark for suspension performance.

Shaped, Swaged and Tapered Tube Set (SST)

Shaped, Swaged and Tapered Tube Set (SST)
Our tubes have been optimized for strength, rigidity, weight, and tube joint interfaces. The tubes are tapered, swaged and shaped providing more control over the precise wall thickness that occurs when the tube takes its final shape. SST.2 tubes transmit all the possible torque a rider may dish out, while maintaining alignment of critical suspension points to ensure the best possible ride.

Ellsworth Factory Tuned Fox Front Fork and Rear Shock

Ellsworth Factory Tuned Fox Front Fork and Rear Shock
With 20 years in the business of suspension tuning, Fox painstakingly custom tunes Ellsworth's rear shocks with our specific original equipment forks to create the ultimate matched ride characteristics. Utilizing Fox's tapered steer tubes; we maximize the stiffness and weight advantages on our frames with our new semi-integrated, tapered head tubes. The suspension performance advantages are showcased by the Ellsworth Frames unparalleled pedal-ability.

Semi-Integrated Tapered Head Tube

Semi-Integrated Tapered Head Tube
The tapered head tube provides superlative strength for razor sharp handling and increased front end stiffness. It improves the overall stack height and allows for an increased bearing surface. This triangulated design, coupled with a lightweight semi-integrated headset, provides the utmost in steering control and handling technology.

Super-formed Pivot Integrated Seat Tube

Super-formed Pivot Integrated Seat Tube
By utilizing heat to prepare the aluminum in the mold, we better control the flow characteristics of the material over conventional hydro-forming, thus maintaining control of the wall thickness in the shapes. New super-formed seat tubes are lighter and stronger than ever.

CNC Machined Rockers

CNC Machined Rockers
Optimized for precision, free-moving linkage performance, Ellsworth's CNC Machined Rockers also contribute to increase overall stiffness. Critical measurements are robotically monitored, assuring the lightest, strongest and incredibly precise machined parts.

Custom 12mm Sex Pins

Custom 12mm Sex Pins
Ellsworth's full suspension bikes utilize a carefully developed attachment system of oversize bearings with the seats and housings, resulting in only a SINGLE bolt-per-pivot assembly. In addition to ensuring accuracy and flawless articulation of the suspension without flex, slop, or binding, the sex pin reduces the need for multiple parts, keeping the Ellsworth full suspension bikes durable, easy to maintain and simple.

 
Asymmetrical Void Hollow Chain Stay

Asymmetrical Void Hollow Chain Stay
One of the most highly engineered parts on Ellsworth full suspension bicycles, the asymmetrical, CNC machined chain stays have been scrutinized and minimized to provide an incredible strength-to-weight ratio. This section is precision aligned to maintain proper wheel tracking and strict, unencumbered suspension movement. The geometry, combined with ICT, moves the precision bearings further apart which acts to stiffen the tail section and
minimize bearing play.

Circumferential Tube-to-Tube Welding

Circumferential Tube-to-Tube Welding
Prior to welding our frames, each tube is milled by hand to align exactly in position before welding. Each tube is then welded around the entire interface, without gaps, for maximum strength and to improve overall efficiency by eliminating unwanted frame flex. This meticulous practice eliminates creaks, extends the life of the frame and provides durability.

Optimized ChainLine

Optimized ChainLine
By working closely with component manufacturers and using aerospace technology in our pivot joints, Ellsworth bikes are designed to align our chain to Shimano or SRAM's exact specifications. Each component of the rear triangle is designed in mind of this critical alignment which reduces drivetrain drag, improves shifting, and overall rider efficiency.

CNC Machined Derailleur Hanger

CNC Machined Derailleur Hanger
Even the most cautious riders know that accidents happen, and on a bicycle that usually means a bent or broken derailleur hanger. Each Ellsworth model is designed with the capability to replace the derailleur hanger. Our Enlightenment models also offer alternate dropouts, for single speed or fixed configurations, in addition to running the latest conventional drive trains.

Anodized Finishing

Anodized Finishing
Carried out under Portland, Oregon's strict environmental control regulations, the anodized finish protects the frame, inside and out, from condensation and other factors, while preventing detrimental fatigue corrosion. Anodizing is done by hand and creates a unique, one-off finish that is durable and less prone to scratching and wear than paint. Our anodizing process also showcases the flawless craftsmanship of an Ellsworth frame, without covering up flaws and imperfections.

Rare Earth Carbon™ Fiber Processing

Rare Earth Carbon™ Fiber Processing
Ellsworth spent three years qualifying our carbon fiber manufacturing facility, material and technique. Our carbon material is certified and tracked from its creation and acquisition through the lay-up in our frame molds, preventing any substitution in material specification or deviation in production from the design specifications. Our state-of-the-art manufacturing facility exercises social responsibility and properly controls the dissipation of carbon particulate in the finishing process through near net molding technique.

Force Vector Anisotropic Design™

Force Vector Anisotropic Design™
(Carbon Composite Frames) Carbon fibers are stranded in a single orientation that creates an anisotropic property (a material with different strength characteristics in different directions). This material attribute can be detrimental to the finished product if not characterized in design, engineering and production. Ellsworth has extensively tested and analyzed force-vectors in bike frames for over 20 years of cutting-edge frame production. The result is an enhanced life and feel of the finished bike frame. Utilizing the unique character of anisotropic material management, Ellsworth creates astounding performance from its Rare Earth Carbon Composite frames.

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