Get ready to witness a game-changer in the cycling world: the first-ever fully bespoke monocoque carbon frame that’s turning heads and redefining what’s possible. But here’s where it gets controversial—can a truly custom carbon bike be both revolutionary and accessible? Let’s dive in.
Italy’s Gregario has just snagged the ‘Best New Builder’ award at Bespoked 2025 (https://www.bespoked.cc/visit), the prestigious handcrafted bike exhibition held in Dresden, Germany, from October 10-12. Their claim to fame? They’re the first to craft a fully bespoke monocoque carbon frame, thanks to a patented variable geometry mould. This isn’t just a bike—it’s a statement.
Gregario boldly declares, “The frame is designed around the rider’s contact points, customizable down to the millimeter in angles and lengths. Even the cockpit is tailor-made, with handlebars and stems adjustable in every dimension.” And this is the part most people miss—the entire process is a unique, step-by-step journey for the customer. It starts with sizing, either in collaboration with a trusted bike fitter or remotely via Gregario’s Digital Sizing web app (https://www.gregariocycling.com/remote-sizing/start/), which uses biometric data to define the frame’s dimensions.
The Gregario Vera AR (Aero Road) bike leverages this patented variable geometry mould, enabling the creation of a seamless monocoque structure without joints—no need for new moulds for each size. This isn’t just innovation; it’s a paradigm shift. Gregario explains, “This approach not only allows for complete customization based on the rider’s position and style but also reduces industrial waste, lowering the environmental impact. Plus, the absence of joints ensures consistent structural quality.”
The result? A high-tech, tailor-made frame built in Italy that rivals industrial monocoque designs while embodying the soul and flexibility of traditional Italian craftsmanship. But here’s the question—is this the future of cycling, or a niche luxury? Let us know what you think in the comments.
Traditional carbon bikes are typically produced in set sizes using pre-preg carbon fibre sheets, moulded with heat and pressure. Moulds are costly, so brands often limit size options. Custom-geometry carbon bikes exist, but they rely on lugs or tube-to-tube methods, which are fundamentally different. Gregario’s technology, however, eliminates these compromises.
The idea was born in 2016 to address the limitations of standard carbon frame sizes, which often force cyclists into suboptimal fits. The solution? A bespoke integral monocoque frame created with a variable mould—a mould whose shape and dimensions can be adjusted to produce different sizes from a single system. From 2017 to 2023, Gregario built a technical foundation and B2B collaborations, culminating in the Eurobike 2023 concept reveal. They deliberately slowed development to prioritize quality and consistency, and now, the Vera AR is here.
The Vera AR is Gregario’s first complete bike model, featuring a frame made with their patented variable geometry mould technology. Produced in a single lamination and autoclaved polymerization process, it’s a testament to Italian design and engineering. Gregario goes beyond the concept of ‘size,’ offering a fully custom-made philosophy. Every detail, from the frame’s angles to the cockpit’s adjustability, is tailored to the rider.
Sizing can be determined by a bike fitter or remotely via Gregario’s Digital Sizing app, which uses neural networks and computer vision for precision. The final fitting customizes the saddle position and component tuning based on the rider’s biomechanics and goals, ensuring a truly bespoke experience.
How does the variable geometry mould work? While Gregario keeps specifics under wraps, their patents offer clues. Essentially, standard mould halves are paired with a customizable insert that determines the frame’s size and shape, even for components like one-piece handlebar/stems.
The Vera AR is a disc brake-equipped aero road bike, with a claimed frame weight of 840g and a fork at 360g. The price? Starting at €6,000 for the frame, fork, and integrated seatpost, and €12,300 for a complete bike—plus tax and shipping. Delivery is expected within two months.
Ready to explore more? Visit Gregario’s website (https://www.gregariocycling.com/) or check out more Bikes at Bedtime here (https://road.cc/show/tags/bike-bedtime/160072). But before you go, we have to ask—is this the future of cycling, or a luxury too far? Share your thoughts below!
