The Small Batch program was created for the Small Batch Cyclocross team — but every Mosaic frame is made in a small batch of oneBen Delaney/BikeRadar
Mosaic founder Aaron Barcheck, at left, with associate Kevin BatchelorBen Delaney/BikeRadar
Each frame starts with an interview, often conducted via a bike shop. After careful consideration of a rider’s fit, physiology and riding preferences, a detailed blueprint is drawnBen Delaney/BikeRadar
The specifications from the drawing come to life on the jigBen Delaney/BikeRadar
The Anvil Journeyman jig dials in each angle precisely. This one shown is for bottom bracket dropBen Delaney/BikeRadar
Head angle is dialed in with this element of the jigBen Delaney/BikeRadar
Mosaic has specific fittings for each width of head tubeBen Delaney/BikeRadar
Head tubes are machined inside the shopBen Delaney/BikeRadar
The raw material at right becomes the finished product at leftBen Delaney/BikeRadar
Each tube is carefully cut for the specified length and anglesBen Delaney/BikeRadar
Tubes are cleaned before weldingBen Delaney/BikeRadar
Barcheck shows the titanium welding torch head (installed) and the smaller steel head (in between thumb and index finger)Ben Delaney/BikeRadar
Each and every joint is carefully welded togetherBen Delaney/BikeRadar
Welding titanium requires a steady flow of argon, an inert gas, to prevent the oxidization of the metal while weldingBen Delaney/BikeRadar
Barcheck makes about 100 frames a yearBen Delaney/BikeRadar
A finished weldBen Delaney/BikeRadar
Barcheck selects parts for each frameBen Delaney/BikeRadar
After a single pass of fuse welding done in the frame jib, the finish pass welding is done, and bridges, bosses and stops are added at that stageBen Delaney/BikeRadar