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Technology

Unmatched, Advanced Engineering Technology

We leverage the latest and most advanced engineering technology in the design of our products. This level of technology is unmatched in the motocross industry.

Our triple clamps are an excellent example of our advanced engineering techniques, so we'll primarily be focusing on them here. More details about that down the page; first we must address common aftermarket parts in comparison to stock components:

Stock vs. Aftermarket

Many riders make the argument that stock is good enough, and for many riders that’s completely true. Riders who demand the absolute best though, must turn to aftermarket components. While the OEM manufacturers have huge budgets and vast design resources, they must also produce a bike affordable for the majority of riders. They aren’t interested in extracting the last 20% of performance out of each and every component, otherwise the bike’s retail price would be astronomical. For this reason, nearly every component design on the motorcycle leaves room for improvement. This is where the aftermarket industry comes in, but the problem is that the capabilities of most aftermarket companies are fairly limited. Take the triple clamps shown here for example:

Stock vs Aftermarket

The image shows a stock Honda lower triple clamp on the left and a leading aftermarket supplier’s version on the right. See the similarities? The aftermarket component, aside from a few differences, is just a machined version of the stock component. Why? Because that’s what they know works; there’s no risk in machining the same design as little has changed from an engineering standpoint. They can offer a product with minimal design effort that they know will work. But will it work the best or even just better than stock? No.

The stock clamps are typically cast (top clamp) or forged (bottom clamp), and their design is heavily driven by that manufacturing process. In general, most stock (and aftermarket) clamps are flat across the top and cored out on the bottom leaving ribs which function structurally. Also though, the ribs aid in manufacturing by maintaining a consistent part thickness and directing the flow of metal through the manufacturing tool. Machined part design is not limited by these manufacturing requirements.

Luxon’s clamp designs (KTM/Husqvarna model shown here) take advantage of this to offer a product with a substantial performance advantage, not just a machined version of the stock parts.

Lighter, Stiffer, and Stronger

Visibly, our clamps are very different to every other clamp on the market. The differences don't end with appearance, though, the performance of our clamps is unmatched - lighter, stiffer, and stronger than the competition. How do we do it? In designing our triple clamps we employ a process called topology optimization using the most advanced engineering software available. This software is the same used by NASA, Formula One teams, and nearly every top automotive and aerospace manufacturer. “Optimized” in this case is not just a marketing buzzword as it is often used; our clamps are as good as it gets.

Topology Optimization Process

The design process begins with a model of necessary material (blue) and material that can be there (green): the optimization variable. Next, optimization results reveal the material that needs to be there: the optimal material distribution. Further analysis and optimization then refine the design minimizing stress while increasing stiffness and reducing weight. The resulting design is truly optimized: lighter, stronger, and stiffer than stock, with added features.

This process is fully automated; there is no human intervention leading the design astray as in traditional FEA methods. The result is a high performance triple clamp design like no other. A precise steering feel and smoother fork action is achieved through increased stiffness and increased strength gives peace of mind in demanding riding conditions. Each performance metric varies depending on make and model of the bike. For example, KTM and Husqvarna triple clamps are very lightweight stock, but lack strength and stiffness. Luxon KTM/Husky clamps are 20% stiffer and nearly twice as strong, all while maintaining the same weight. Stock Yamaha clamps, on the other hand, are adequately stiff as-is, but very heavy. Our design goals for the Yamaha clamps were to maintain the stock stiffness level while reducing weight. In the end, our Yamaha clamps came out 2% stiffer, 25% stronger, and 363 grams (0.8 pounds) lighter than stock!

Performance Features

Our advanced technology doesn't stop at the upper and lower clamps, the entire assembly is designed for performance. Grade 5 titanium bolts come standard for further weight savings. Lower bar mounts are one-piece and dramatically stronger than stock making twisted bars a thing of the past. The bar mounts are also rubber mounted to reduce vibration and reversible for adjustable reach.

Multiple design details add to the performance of the Luxon clamps. Our triple clamps feature opposing fork tube clamps to eliminate the slippage experienced with many stock designs. Additional features such as an integrated lower mount for the HPSD (Honda Progressive Steering Damper) eliminate brackets and other band-aid fixes used by other companies.

Manufacturing and Quality

Highly advanced design must be mated to advanced manufacturing to bring a product to life. Luxon MX uses the latest in CNC machining technology to manufacture our triple clamps. Precision machining with intricate surfacing delivers product quality typically only seen in works level factory parts.

Nearly all of our products are manufactured in-house at our San Diego facility to ensure the highest quality standards are met. Our clamps come with the steering stem and lower bearing pre-assembled and with detailed instructions for trouble free customer installation.

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