BEAST Components - Carbon Handlebars


Carbon is black? No, also red or blue, as BEAST Components impressively pulled off. The young Dresden-based company has already caused quite a stir with its lightweight high-end carbon components for MTB and Road bikes. The makers of BEAST can draw on a great deal of know-how from their time at the Lightweight Construction Institute of the TU Dresden and experience from projects for the automotive and aviation industries. All components, be they wheels, handlebars and stems, saddles and seatposts or bottle cages, are extensively tested using the finite element method even before prototype construction begins. The finished parts are put through their paces at the Zedler Institute. The result is durable, lightweight components that are among the best on the market. The entire process, from the idea to the finished product, takes place in Dresden.

High-end carbon components for your bike, Made in Germany

BEAST Components is a young company based in Dresden, Germany, which is fully committed to carbon. Behind BEAST are passionate mountain bikers who put their knowledge of lightweight construction and carbon with the concentrated professionalism of experienced engineers into the development and production of outstanding components for bicycles. And the result is simply outstanding.

We were able to see for ourselves the high-quality production of handlebars, stems, wheels, saddles and seatposts on site in Dresden. The carbon factory is located in the industrial area northeast of the Saxon capital and you can feel it as soon as you enter the factory building: Here passion and professionalism go hand in hand.

The heads and makers of BEAST Components, above all Mirko Filler, studied and worked at the Lightweight Construction Institute at the Technical University in Dresden before setting up their own brand. During this time, they have implemented a wide variety of projects for both the automotive and aerospace industries, and the components they develop and produce for bicycles now benefit from this experience. "What fascinated me most was the consistency with which scientific methods are used here to optimally exploit the outstanding properties of carbon fibres for the products," says Christoph, who was on site for us. "Through their scientific approach to the construction of the components, they can go to the limits of what is physically feasible, because they know very well where these limits lie. The result is perfect handlebars or wheels that are optimally balanced between weight, safety and aesthetics."

And this quality of production can be seen in the flawless components: Only a thorough polishing finishes the handlebars, rims or saddles, so that the fibre structures from which the products are made are clearly visible. This method is mercilessly honest and doesn't allow any mistakes during layering. You see what you get - You can see from your handlebars the precision with which the layers are built up and how cleanly and precisely, not to say in detail, they work here.

But before the time comes and the parts are actually put into shape, they have gone through an extensive process from the initial idea to prototype construction. Even before the first samples leave a mould at BEAST Components, the strength and deformation properties of the components are tested in complex simulations using the finite element method. In this way, it is possible to calculate down to the last detail how the products are constructed and how the individual layers of carbon fibres must be laid in order to achieve the best possible ratio of weight to stability as well as flex to damping. "We know even before testing on our test stations that our components will hold," says Mirko with the calm confidence of those who know exactly what they are doing and what their products are capable of. It is not only his own test stations that show him on a daily basis what stresses the components can withstand without damage. Independent testing institutes such as the Zedler Institute in Ludwigsburg or EFBE Prüftechnik GmbH in Walltrop also confirm the safety of BEAST products, which are also approved for Downhill bikes.

The production of series-ready components then takes place with absolute precision only a few rooms away. First, the different layers are cut by computer. Depending on the product, they are produced either in the prepreg autoclave process, in which the cooled, pre-impregnated fibre structures are laid into the mould layer by layer and according to a precise design plan, after which they are cured in the autoclave under temperature and pressure. Or in Resin Transfer Moulding (RTM), in which the dry fibre structures are placed in the mould in the appropriate spot and according to the design plan. In the following injection process they are soaked with resin and hardened by heat. Especially the layering, i.e. the laying out of the individual carbon layers, requires precision, experience and skill, since fibre by fibre, layer by layer, the handlebars or the wheel are built.

After curing, each product is meticulously tested. With an endoscope, for example, the handlebars can also be examined inside for defects or unevenness. Only constructively perfect components are then used in optical quality control, where minor defects are repaired. Products with an optically defective carbon structure, with bubbles or dents are sorted out here. "Our customers expect perfect components all around and we want to offer them these", is Mirko’s credo.

Our visit to BEAST Components leaves us completely convinced that with this brand we can offer you absolutely high-quality carbon components that are impressively light and comfortable, at the same time absolutely stable and safe. A 5-year manufacturer's warranty and lifetime crash replacement for the first owner (50% discount on the RRP) testify to the trust they place in their own products. And so Christopher's commitment to BEAST Components comes as no surprise:

"For a long time, I only rode aluminium because of the safety concerns about carbon. After my visit at BEAST Components I have to say: Well-made carbon handlebars are safer than an aluminium bar. I trust BEAST Components."

Impressions from our visit to BEAST Components