I’m standing in an unassuming industrial property on the outskirts of Monza, close to Milan, Italy, outdoors an aged white constructing that leaves only a few clues as to the exercise that goes on inside. Aside from the two-wheel brand that sits atop the doorway, there’s nothing that claims bicycles in any respect, not to mention a producer of such excessive esteem. That is, in fact, till you step inside.
Having not too long ago visited Specialized’s headquarters in Morgan Hill, California, for the same behind-the-scenes tour, I used to be eager to see one thing from the opposite finish of the dimensions, so I’m on the manufacturing unit and headquarters of Passoni, one of the vital extremely revered {custom} producers of titanium bicycles on the earth.
Founded by Luciano Passoni in 1989, the model claims the title of being the primary firm to fabricate titanium bicycles in Italy, and these days it seems round 350 bikes per 12 months. Upwards of 80% of these are ‘made to measure,’ with {custom} geometry, earlier than being shipped all over the world.
With a no-secrets have a look at the manufacturing unit, nothing was off-limits as my host, and Passoni’s product supervisor, Matteo Visentini took me on a short journey by means of the model’s historical past earlier than we entered the manufacturing unit, met the women and men behind the model, and I witnessed first hand among the steps on this millimetre-accurate course of.
The historical past
Starting with a tour of the model’s in-house showroom. While it isn’t dissimilar to the Specialized showroom in that they had been each set as much as have fun key moments within the manufacturers’ histories, that is the place the similarities finish. The Passoni showroom was a small room, full with not more than 20 bikes, a desk strewn with spectacular parts and collaborations. A stroll by means of time may be accomplished in mere seconds, however we spent a little bit longer discussing the small print.
This small room is dwelling to among the model’s vary, together with a really particular buyer bike, quickly to be delivered (Image credit score: Josh Croxton)In Passoni’s early years, titanium was mostly utilized in aerospace and navy software, the place its excessive strength-to-weight ratio, corrosion resistance, and warmth resistance had been valued. As such, it was produced virtually completely in sheet type which might be used for bigger plane parts, quite than tubes, for bicycles.
As a end result, when creating this time trial body within the early ’90s, Passoni needed to form and fold the sheets accordingly, therefore the fold which may be seen on the downtube (Image credit score: Josh Croxton)The model was additionally creating one-piece handlebars lengthy earlier than they had been cool. This piece was one of many many experiments from Passoni within the early ’90s. It was used for cyclocross racing and even in MTB races because the model experimented with new positions and shapes. (Image credit score: Josh Croxton)This monitor handlebar was one other early one-piece cockpit, however as a result of wall thickness of titanium used, they might be recognized to fail beneath stronger riders (Image credit score: Josh Croxton)Titanium was the model’s begin, however the firm’s founder, Luciano Passoni, was targeted on making nice bikes, not merely nice titanium bikes. As a end result, when carbon fibre grew to become the fabric of alternative, he adopted go well with, creating this prototype (Image credit score: Josh Croxton)Its complexity, whereas little question a transparent speaking level… (Image credit score: Josh Croxton)…was sadly too excessive to provide cost-effectively (Image credit score: Josh Croxton)As a end result, Passoni scaled again and created this, the Animus Titanium… (Image credit score: Josh Croxton)…which, when translated from Latin, means ‘Titanium Soul’… (Image credit score: Josh Croxton)…referencing the body’s dropouts, backside bracket shell and head tube, that are all made utilizing titanium components. The Animus grew to become the model’s first manufacturing carbon bike (Image credit score: Josh Croxton)The ‘Honey Comb Technology’ stickers point out that the inside of the seatstays and chainstays function a honeycomb construction inside, quite than being hole (Image credit score: Josh Croxton)Later, the model moved to this body, which makes use of carbon tubes for the entrance triangle, joined by a titanium rear triangle and head tube (Image credit score: Josh Croxton)The head tube options carbon inside, and is completely handmade, no laser-cutting was accessible on the time (Image credit score: Josh Croxton)It was made on this very manufacturing unit, simply outdoors Monza on the outskirts of Milan (Image credit score: Josh Croxton)It was referred to as the Mito; Italian for ‘delusion’ (Image credit score: Josh Croxton)That design later led to the XXTi, or the Twentieth-anniversary mannequin, which launched on the model’s Twentieth birthday in 2009. As you possibly can see, extra of the body has made the swap again to titanium, with solely the seat tube and glued seatpost getting the carbon remedy (Image credit score: Josh Croxton)Lasers had been accessible by this level, and had been used to type these shapes (Image credit score: Josh Croxton)Nowadays, Passoni goes a step additional, connecting carbon fibre and titanium proper on the supply by weaving hair-width strands of titanium into the carbon fibre weave. It’s a expertise made proper right here in Milan, and can be present in Pagani supercars. It is alleged that the titanium strands are capable of facilitate better vibration absorption, and thus the completed product presents the same remaining journey high quality to a titanium body, in a lighter and extra aero-mouldable product (Image credit score: Josh Croxton)10 years after that mannequin, for the model’s thirtieth anniversary, Passoni launched the Vinci. Just 30 had been made, and that is quantity 20 (Image credit score: Josh Croxton)Each are given a gold-plated head tube badge, plus this gold-plated plaque on the seat tube denoting its quantity within the restricted sequence (Image credit score: Josh Croxton)This specific construct totals a staggering 30,000 Euros (Image credit score: Josh Croxton)It is full with Passoni-branded THM Clavicula carbon cranks, Carbon-Ti chainrings, and Campagnolo Super-Record EPS (Image credit score: Josh Croxton)The intricate element on the titanium joint with the carbon tube is absolutely neat (Image credit score: Josh Croxton)The bar and stem are additionally made by THM (Image credit score: Josh Croxton)And overlook bar tape, these are wrapped utilizing leather-based… (Image credit score: Josh Croxton)…which is stitched into place by hand, no much less (Image credit score: Josh Croxton)There’s a leather-covered saddle, full with the Passoni brand, too (Image credit score: Josh Croxton)Even the Elite Fly bottles have been wrapped in a leather-based end, as a result of why not? (Image credit score: Josh Croxton)The consideration to particulars is really beautiful, as highlighted by the imprint of the Passoni brand on the seatstay bridge (Image credit score: Josh Croxton)Passoni’s proprietor’s gravel bike, nonetheless coated in mud from its final journey, additionally sits within the showroom (Image credit score: Josh Croxton)It’s known as the Cicloprato, and it launched in 2018 (Image credit score: Josh Croxton)Passoni was chosen by Shimano to function amongst a really choose group of producers to be allowed to make use of the silver GRX gravel groupset (Image credit score: Josh Croxton)Passoni presents three completely different finishes to its frames. This, the premium end, takes over 30 hours of sharpening (Image credit score: Josh Croxton)Passoni presents three completely different finishes to its frames. This, the premium (Image credit score: Josh Croxton)Even in the dead of night indoor manufacturing unit lighting, this completed body shines brightly (Image credit score: Josh Croxton)The welds, designed to be invisible, had been described by product supervisor Matteo Visentini as wanting like “liquid steel” (Image credit score: Josh Croxton)The second-tier end, referred to as Vinci, because it was launched alongside the body of the identical title, options ‘tough’ welding. Rough is an unfair phrase, although, because it nonetheless appears to be like extremely neat (Image credit score: Josh Croxton)The third tier is sandblasted, with a visibly matte end (Image credit score: Josh Croxton)The model often collaberates on particular tasks, equivalent to a latest restricted version winter undertaking that paired a gravel bike with a pair of skis, full with ski binding specialists, ATK (Image credit score: Josh Croxton)Passoni as a model is eager to have its brand on as lots of its companions’ merchandise as doable… (Image credit score: Josh Croxton)It is the one model to have its personal brand on THM cranks, whereas additionally that includes on the identical model’s caliper brakes and Selle Italia’s saddles (Image credit score: Josh Croxton)This hub, from aerospace engineers Gosiko, is made utilizing 4 bearings, pivoting washers, and is totally beautiful. They can be found to spec on Passoni bikes for a cool £7,000. That’s simply the hubs (Image credit score: Josh Croxton)
Into the manufacturing unit
Out of the showroom and onto the manufacturing unit ground, there have been no secrets and techniques right here. Unlike my latest journey to Specialized, there have been no “don’t {photograph}” requests, nor closed doorways – effectively, there was one, which I’ll clarify later – and no secrets and techniques. I used to be given complete freedom to go wherever and {photograph} no matter I needed.
Wooden packing containers are an necessary a part of any framebuilder’s workshop. Each field represents a buyer, and so they start life as a field filled with tubes and dropouts, and emerge as a fully-fledged body able to fly the nest. These are all completed and ready to be constructed (Image credit score: Josh Croxton)Sitting subsequent to them is three bikes. Two of that are employees bikes, the third is ready to be shipped (Image credit score: Josh Croxton)Down a brief walkway and into the principle framebuilding space, I handed this body, constructed by one of many staff in 2009. That similar worker has been with the corporate for 30 years (Image credit score: Josh Croxton)Titanium is extremely reactive and might react with oxygen, nitrogen, and different gases within the air at excessive temperatures, resulting in the formation of brittle and porous welds. In order to forestall this, welding titanium usually requires a extremely managed atmosphere that’s free from oxygen and different contaminants.
Such an atmosphere is created on this argon chamber, which replaces the air with inert argon fuel. This very one was purchased from Alfa Romeo in 1989, and each single one in every of Passoni’s titanium frames within the firm’s historical past has handed by means of it (Image credit score: Josh Croxton)The frames can’t be absolutely welded outdoors the chamber for causes already talked about, however by utilizing a highly-skilled technique of welding, referred to as gas-shielded steel arc welding, the tubes can first be ‘tack welded’ collectively into their required form, making the welder’s life simpler as soon as the body is contained in the argon chamber (Image credit score: Josh Croxton)Due to the fee and time it takes to change the environment contained in the chamber, the welder will usually fill it with three frames at a time. They will then work by way of these gloves, with nothing greater than this six-inch window for visibility. Note the sliding door over the window… (Image credit score: Josh Croxton)…that sliding door is actuated by way of this pair of brake cables (Image credit score: Josh Croxton)This is the view from the opposite facet (Image credit score: Josh Croxton)The manufacturing unit ground, full with tube mitering machines to the left, three sharpening stations to scrub up welds, and across the nook to the best, a body geometry jig and arc welding station (Image credit score: Josh Croxton)This, the primary of the mitering machines, is used on the bigger tubes, such because the down- and top-tubes (Image credit score: Josh Croxton)This one is for smaller tubes, equivalent to chain- and seat-stays (Image credit score: Josh Croxton)The tube is positioned onto this multi-axis adjustable base, which is then poisitioned beneath the opening noticed (Image credit score: Josh Croxton)Given titanium’s reactivity with oxygen and nitrogen at excessive temperatures, fluid is ejected from this nozzle in the course of the minimize to maintain the steel cool (Image credit score: Josh Croxton)A detailed up right here reveals a recently-cut tube (Image credit score: Josh Croxton)After tubes have been minimize on the right angle, they arrive over to this space, the place this jig is ready up with the shopper’s required geometry (Image credit score: Josh Croxton)The joints are checked, after which hand-filed for accuracy if required (Image credit score: Josh Croxton)I returned half-hour later to test progress, and what was beforehand a head tube and a seat tube has now gained chainstays (Image credit score: Josh Croxton)This space can be the place uncooked body components are saved, together with the principle tubes, backside bracket shells and extra. Each is minimize to measure earlier than getting used (Image credit score: Josh Croxton)Passoni makes use of titanium tubes from British model Reynolds (Image credit score: Josh Croxton)The small components, together with inside cable finish stops, bottle cage bosses and bag mounting factors are saved right here (Image credit score: Josh Croxton)These dropouts are the one body half that Passoni would not make, as a substitute importing them from the USA and modifying them. It does make different variations, although. This is only one of some dropout choices accessible to Passoni clients, as we’ll get into later (Image credit score: Josh Croxton)After they have been filed for accuracy, tack welded into form, and correctly welded within the argon chamber, they’re left to chill, after which they arrive to one of many sharpening stations, the place rotary instruments are used to shine away the tough edges (Image credit score: Josh Croxton)Here is an instance of a uncooked weld, previous to any sharpening (Image credit score: Josh Croxton)Dozens of bits are used, with completely different shapes used for various joints (Image credit score: Josh Croxton)Here, one of many group is engaged on the driveside dropout. Remember this can be a course of that takes upwards of 30 hours in complete (Image credit score: Josh Croxton)Smaller-headed bits are used for tight areas, whereas the underside bracket makes use of bigger bits for sooner and smoother work (Image credit score: Josh Croxton)This 18-year-old is an aspiring body builder, however I’m informed he should work his approach from this finish of the manufacturing unit to the opposite. I’m pretty positive this was a half-joke, but it surely did seem that the duties grew to become extra sophisticated and complicated as you went on (Image credit score: Josh Croxton)He rides an outdated Giant TCR, and amusingly, in contrast to the 2009 Passoni that was proudly propped up towards a wall in one of many constructing’s walkways, the Giant was hidden, actually and deliberately, in a again storage room out of sight (Image credit score: Josh Croxton)Finished frames are then introduced right here, to the literal vault on the centre of the model’s HQ (Image credit score: Josh Croxton)The vault is unsurprisingly the place the costly stuff is saved, together with inventory of parts, equivalent to Campagnolo groupsets and wheels, in addition to half-built bikes (Image credit score: Josh Croxton)As earlier than, packing containers equal clients, and right here the packing containers are crammed with not solely the body however the parts that can go onto them.
On the entrance of every is a number of sheets of paper, holding the body serial quantity, construct spec, geometry chart and extra. The serial quantity is coded, T for titanium; 23 for the 12 months 2023; then 001, 002 and so on denoting the order during which the acquisition got here by means of from the workplace to the manufacturing unit.
However, that final half is not truly completely true, as within the early a part of the 12 months particularly, many Passoni clients need to select their very own. In China, for instance, the quantity 8 is deemed fortunate, because it sounds much like the phrase for ‘prosperity,’ whereas 4 is unfortunate, because it sounds just like the phrase for ‘dying’ (Image credit score: Josh Croxton)Passoni has additionally begun anodising frames, which is a course of that manipulates the oxide layer on the fabric’s floor by way of electrical present and outcomes on this stunning end.
In complete, the model builds and sells round 350 bikes per 12 months, and whereas it does manufacture off-the-peg sizing runs, greater than 80% of its buyer base seeks custom-made geometry (Image credit score: Josh Croxton)It’s not all unfinished frames in right here, although. Some employees bikes reside right here, others are right here for restore work (Image credit score: Josh Croxton)These days you possibly can’t talk about titanium with out getting onto the topic of 3D printing the stuff, and naturally, Passoni has began engaged on this too (Image credit score: Josh Croxton)These dropouts are discovered on the model’s carbo-titanium body (utilizing the titanium-blended carbon fibre proven earlier) referred to as the Fidia Disco. They are made simply 10km away from Passoni’s HQ (Image credit score: Josh Croxton)The early prototypes had been first explored by the model in 2018 (Image credit score: Josh Croxton)The printing course of has come a good distance within the 5 years since (Image credit score: Josh Croxton)
Bike match
You is likely to be questioning how a buyer would get a body that’s completely suited to them in the event that they did not know what geometry they want. If you are among the many fortunate few who can take into account Passoni amongst their subsequent bike, you may even be questioning the way you’d go about discovering that out. Naturally, Passoni handles that too, so to take this complete gallery again to the chronological starting of a purchase order journey, we have to have a look at bike match, and up a steel stairway to a mezzanine ground is an space devoted to the method.
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The model additionally has match companions all all over the world, as a result of not all of its clients are primarily based in Italy, and even Europe, however Passoni would naturally favor its clients to make the journey to its Milan headquarters in order that it could actually present probably the most full and private strategy doable.
I discussed earlier that there was one closed door, and now it is time to clarify. Among the services here’s a sauna, devoted to serving to guarantee clients are versatile and cozy as doable. It was behind an not noticeable closed door that I politely assumed was unimportant, therefore no picture.
The first step is measuring the rider, masking issues equivalent to total peak and limb size (Image credit score: Josh Croxton)The bike match bike is round 20 years outdated, however works simply in addition to ever (Image credit score: Josh Croxton)Sit-bone measurement is used for saddle alternative, whereas foot measurement helps with finer particulars (Image credit score: Josh Croxton)If a rider has a body they need to replicate, they will carry it alongside an dhave it measured utilizing this jig, which by the way, was made by Passoni itself on this very constructing (Image credit score: Josh Croxton)The bike match space overlooks the room during which accomplished frames are constructed up into rideable bikes, earlier than being boxed and shipped all over the world (Image credit score: Josh Croxton)This work bench is technically dedicated to the bike builder, however there are all method of instruments, together with a hack noticed for causes I by no means realized (Image credit score: Josh Croxton)This body will go to its buyer as-is, so a fast wipe-down removes any grease and dirt from being dealt with, earlier than it’s wrapped and boxed (Image credit score: Josh Croxton)
