Sage Cycles Unveils Revolutionary Titanium Full-Suspension Downcountry Mountain Bike

Experience the Future of Mountain Biking with Project FAF: Unmatched Performance, Precision Engineering.

The Genesis of Innovation: A Decade-Long Vision Takes Shape

Since 2012, David Rosen, the visionary behind Sage Cycles, harbored a dream of creating a full-suspension mountain bike. After years of conceptualization, diligent design, extensive prototyping, and rigorous testing, his ambition has materialized into Project FAF. This pioneering titanium full-suspension mountain bike stands as a testament to perseverance and cutting-edge engineering, signaling a new era for Sage Cycles and the wider cycling community.

Project FAF: A Prototype Forging Its Identity in the World of Mountain Biking

Currently designated as Project FAF, this innovative XC/downcountry bike is undergoing its final refinements before transitioning into full production. Rosen, emphasizing a collaborative design process, revealed that the prototype benefited from the expertise of an engineer proficient in CAD modeling and kinematics. This partnership ensured that the FAF's design is not only visionary but also meticulously engineered for optimal performance.

Revolutionary Suspension Design: Harnessing Titanium's Unique Properties

The FAF incorporates a single-pivot flex-stay suspension system, offering 120mm of front travel and 115mm at the rear. This design prioritizes simplicity and ease of maintenance. Rosen masterfully utilized titanium's inherent flexibility, shaping and ovalizing the chainstays and seatstays in distinct directions, and employing varied tube diameters to create a dampening effect. The outcome is a bicycle that promises exceptional stiffness and responsiveness on diverse terrains, enhancing both climbing efficiency and downhill control.

The Dawn of 3D-Printed Titanium in Bicycle Manufacturing

A pivotal advancement enabling Project FAF's realization is the increased accessibility of 3D-printed titanium components. Each frame integrates six such parts, including the dropouts, chainstay yoke, bottom bracket cluster, and seatstay bridge, all produced in Oregon. These 3D-printed elements feature a raw, unpolished texture, deliberately contrasting with the frame's smooth titanium tubes. Rosen appreciates this aesthetic, highlighting the industrial finish against the polished surfaces.

Investment in Excellence: The Premium Craftsmanship of Project FAF

The frameset of Project FAF is projected to be priced between $10,000 and $15,000, reflecting the high costs associated with its sophisticated production. This includes extensive 3D printing, premium titanium tubing, intricate welding, and skilled labor. While the final cost will be determined upon production, the frameset will include a shock, seat post collar, and axle. Buyers will also have the option to choose from complete bike builds, potentially featuring SRAM or Shimano XTR components with RockShox or Fox suspension, respectively.

The Confluence of Materials and Manufacturing: A Glimpse into Project FAF's Construction

Project FAF is constructed from high-grade Grade 9 (3/2.5) US-sourced titanium tubing, seamlessly integrated with Grade 5 (6/4) 3D-printed titanium components. The bike's custom-engineered shock linkage is crafted from a durable aluminum alloy, ensuring both strength and performance. This combination of materials underscores Sage Cycles' commitment to quality and innovation.

A Rising Trend: Titanium, USA-Made Full-Suspension Mountain Bikes

Project FAF joins a growing cohort of high-end, USA-made titanium full-suspension mountain bikes. Brands like Viral, Reeb, Stinner, Foes, and Lenz are increasingly recognized for their domestically produced metal bikes. Furthermore, Ibis's recent announcement of US production for their new Ripley SL carbon fiber frames highlights a broader industry movement towards localized manufacturing and premium quality.

Anticipation Builds: Final Adjustments and Future Deliveries

Rosen is meticulously overseeing the final validation of the bike's geometry across all sizes and confirming optimal tire clearance. Although current geometry figures may see minor adjustments before production, the bike is nearing perfection. A last-minute decision to switch from an IS brake mount to a post mount will offer riders greater flexibility in brake choices, accommodating newer models like SRAM's Motive and Maven brakes. Orders for Project FAF can be secured with a $1,000 non-refundable deposit, with initial deliveries anticipated in the first quarter of 2027. Rosen underscores that for this "halo bike," akin to a luxury vehicle, customization options will be extensive, ensuring each owner receives a truly bespoke machine.