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Smart Manufacturing: A New Era for the Bicycle Industry

Intelligent Welding · Seamless Grinding · Efficient Manufacturing

Smart Manufacturing Drives Bicycle Industry Upgrades

With the growth of the electric bicycle market, the demand for safety and stability in frames has increased, making it difficult for traditional manufacturing methods to meet these requirements. Automation and smart manufacturing not only enhance production efficiency but also ensure process stability and product quality, safeguarding user safety.

DS Technology provides a comprehensive vertically integrated solution covering material preparation, welding, surface finishing to final quality optimization, helping customers build efficient and stable smart manufacturing processes.

  • Material Preparation: 3D laser cutting systems ensure tube precision to meet automated welding requirements. We also offer automated equipment for aluminum alloy casting processes, including investment casting, gravity casting, and die casting to ensure stable production and high quality.
  • Welding: Our intelligent welding system adapts to small batch, high-mix production with fast line and mold change capabilities reducing reliance on skilled welders while ensuring high precision and consistency, achieves the highest automatic welding rate, improves production efficiency, and lowers labor costs.
  • Surface Finishing: We provide complete vertical integration, covering consumables, grinding and polishing tools, and surface finishing processes. Our robotic surface finishing system ensures consistent surface quality for aluminum alloy and carbon fiber frames while preserving design details to meet high aesthetic standards in the end market.

Additionally ,our dust isolation mechanism completely contains dust within the equipment, preventing exposure to high-dust environments and enhancing workplace safety and health standards.

Aluminum Alloy Bicycle Frame Manufacturing Process – Material Preparation

Automation in Casting Process

Providing precision casting, gravity casting, and die casting automation equipment, along with process consulting services to assist customers in optimizing production processes, enhancing manufacturing capabilities, and ensuring high consistency and stable quality of aluminum alloy components.

  • Automation Equipment Implementation: Reduces manual operations and improves production stability.
  • Process Optimization Support: Enhances process efficiency and consistency with expert consultation.
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Precision Casting
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Gravity Casting
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Automation in Machining Process

For tube, casting, and component machining we provide automated loading and unloading solutions for machine tools to effectively improve production efficiency, reduce manpower requirements, and ensure stability and precision in component machining.

  • Automated Loading and Unloading System: Minimizes manual intervention and enhances equipment utilization.
  • Stable Machining Quality: Ensures component dimensional accuracy and improves production quality and yield.

Robotic 3D Laser Cutting System

DS Technology’s 3D laser cutting technology enables precise machining of various tubes, ensuring dimensional accuracy and seamless integration with automated welding systems. We also provide design and manufacturing of laser cutting jigs to create a comprehensive smart manufacturing solution that optimizes machining quality and production efficiency.

  • High-Precision Laser Cutting: Ensures dimensional consistency to meet automated welding requirements.
  • Jig Design and Manufacturing: Optimizes cutting quality and enhances machining stability.
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Robotic Surface Finishing System (Deburring, Grinding, Polishing)

For tubes and castings, DS Technology provides a professional and vertically integrated surface finishing solution covering consumable selection, grinding and polishing tools, belt applications, process methods, and offline robotic path programming . This solution offers comprehensive technical support and consulting to enhance product quality and ensure design detail integrity, meeting various customer surface finishing needs.

  • Comprehensive Surface Finishing Solution: Covers consumables, tools, processes, and technical support.
  • Enhanced Product Quality: Ensures a smooth and uniform surface that meets high standards.

DS Technology possesses exclusive weld seam grinding technology that enables seamless weld removal on aluminum alloy welded frames, achieving an integrated frame appearance and enhancing overall product aesthetics and market competitiveness.

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Integrated Frame Grinding

Eliminates weld seam marks to create a smooth, seamless appearance.
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High-Precision Grinding Technology

Ensures perfect integration of welded areas with the rest of the frame.
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Robotic Automated Grinding

Ensures consistency, improving production quality and efficiency.

Precision casting or gravity casting parts combined with robotic weld seam grinding technology, creating a seamless carbon fiber-like appearance

By integrating precision casting or gravity cast parts with robotic welding and weld seam grinding systems, DS Technology offers a complete manufacturing solution that enables aluminum alloy frames to achieve a seamless carbon fiber-like appearance.

  • Precision Casting / Gravity Casting Applications: Enhances part strength and accuracy while reducing machining and assembly requirements.
  • Robotic Welding Technology: Ensures welding precision, improving structural stability and consistency.
  • Exclusive Weld Seam Grinding Technology: Eliminates weld seam marks, creating a smooth and seamless appearance.
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Through smart manufacturing, DS Technology helps customers enhance product quality and market competitiveness, achieving the best manufacturing process for aluminum alloy frames with a carbon fiber-like appearance.

Aluminum Alloy Frame Manufacturing – Welding Process

Full-Feature Automatic Welding System

Suitable for small-batch, high-mix and large-scale production with high precision and advanced automation to ensure welding standardization and reduce reliance on skilled welders.

  • AMR Integration Support: Enables automatic mold changing and material feeding, enhancing production flexibility and efficiency.
  • Centralized Control System: Monitors welding parameters in real-time to ensure consistency and stability.
  • Equipment Standardization: Identical welding parameters and path programs can be applied to different full-feature welding machines, ensuring stability, easy management, and process consistency.
  • Quick Mold and Line Change: Allows offline testing and optimization of welding parameters and paths without occupying the production line. Once tested, automated welding can be quickly implemented, reducing production changeover time.
  • Offline Programming Software Support: Integrates with Robotmaster, significantly reducing automated welding program development time and improving production efficiency.
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Cost-Effective Automatic Welding System

Ideal for small and medium-sized enterprises or early-stage automation implementation, offering a high-value automatic welding solution.

  • Reduced Labor Dependence: Minimizes the need for skilled welding technicians, enhancing production stability.
  • Flexible Configuration: Offers single-station & dual-station options to meet different production capacity needs.
  • Enhanced Efficiency and Quality: Ensures stable welding quality and improves overall production efficiency.

Welding Fixture Design & Manufacturing

Our DS welding fixtures are specifically developed to enhance welding precision and consistency by leveraging over 15 years of automated welding expertise and scientific optimization, ensuring optimal welding performance.

  • Robotmaster Welding Path Simulation: Ensures an automation rate of over 90% for welding.
  • Precision Fixture Design: Enhances robotic welding stability and production efficiency.
  • Supports Small-Batch, High-Mix or Mass Production: While ensuring welding consistency and quality.
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Modular Bicycle Frame Automatic Welding Production Line – Efficient, Intelligent, Standardized Manufacturing​

DS Modular Frame Welding Production Line uses fully automated welding technology combined with 3D laser cutting, intelligent welding systems, and AMR automated transport to create a high-capacity, low-labor dependency, standardized quality smart manufacturing solution.

Capacity Conditions

1

Working Conditions

  • Daily working hours: 24 hours
  • Monthly working days: 22.5 days
2

Production Shifts

  • Three shifts
3

Standard Frame

  • Cycle Time: 3 minutes/unit
  • Annual production capacity: 129,600 units
4

E-Bike Frame

  • Cycle Time: 5 minutes/unit
  • Annual production capacity: 77,760 units
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Production Line Overview​

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24-hour continuous production with three shifts operation to ensure high production capacity output

2

The entire line uses automated welding and 3D laser cutting technologies to ensure high precision and consistency

3

Equipped with the AMR automated logistics system to reduce manual handling and improve production efficiency

4

Suitable for both standard bicycle and electric bicycle frames, supporting diversified product manufacturing

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Production Line Technology Highlights

3D Laser Cutting Zone

Front Triangle Frame Spot Welding Zone

Front Triangle Frame MIG Welding Zone

Front Triangle Frame Cooling Zone

Front Triangle Frame TIG Smooth Welding Zone

Rear Triangle Frame MIG & TIG Smooth Welding Zone

Frame Assembly Welding Zone

AMR Automated Transport

Intelligent Handling System Design

Production Line Advantages

1

Fully Automated Welding

Ensures stable welding quality, reduces manual intervention, and improves welding consistency

2

Standardized Production Process

Data-driven production to shorten welding cycles and increase output capacity

3

Intelligent Logistics Integration

AMR automated handling reduces manual handling costs, minimizes human errors, and enhances production flow efficiency

4

Diverse Application Support

Suitable for a variety of products, including standard bicycles and electric bicycle frames, with the flexibility to adjust automation levels based on customer requirements

5

Intelligent Management and Data Analytics

Paired with the DS Cloud AI intelligent management system, providing real-time monitoring, data analysis, and welding parameter management to ensure stable line operation and traceability of quality

6

Rich Experience in Mass Production Design

With multiple successful cases, we have provided mature automatic welding solutions for international brands, ensuring the best industrial manufacturing standards

Why Choose DS Technology to Build Your Bike Frame Smart Manufacturing Factory?

DS Technology has over 15 years of experience in bike frame automation, utilizing smart manufacturing, automation technology and comprehensive plant output capabilities to provide complete solutions for the bike industry, covering material preparation, welding, surface finishing, quality inspection, and smart production management to help businesses create efficient, stable, and sustainable smart manufacturing factories.

  • Complete Automated Process: From casting, laser cutting, welding to surface finishing, offering end-to-end smart automation to enhance production efficiency and quality consistency.
  • Exclusive Welding Bead Grinding Technology: Achieves one piece frame without welding bead construction with a carbon fiber-like high-end appearance helping customers improve their product's market competitiveness.
  • Carbon Fiber Grinding Automation: Solves the labor shortage in carbon fiber grinding and reduces dust exposure risks to operators with dust isolation covering, creating a safer work environment.
  • Smart Welding and Jig Design: Provides full-featured and budget version automatic welding equipment paired with precision jig design to ensure stable and consistent welding quality, improving automatic welding efficiency.
  • Data Monitoring and Smart Production Management: Integrates DS Cloud AI and DS MES for real-time production data monitoring, improving management efficiency and production transparency, ensuring smooth operations.
  • ESG-Friendly Manufacturing: Through smart manufacturing reduces energy consumption and carbon emissions while creating a safe, low-dust working environment to protect employee health, meet international environmental standards, and help businesses achieve sustainable development.

Choosing DS Technology means choosing the most comprehensive and professional smart manufacturing solutions, helping businesses enhance production efficiency, reduce labor costs, and move toward a safer, more efficient, and sustainable future!

© Da Shiang Technology Co., Ltd | DS Technology 2025