Clearly you’ve got a price list to back that up, so go on then.
And explain why some companies buy ‘open mould’ frames, why other companies retain moulds and use them for lower spec frames (using cheaper CF) and why Giant and Norco make “carbon’ bikes with alloy rear triangles when carbon and moulds are so cheap.
Well that would depend on what the specification was that was handed to the production engineers from the marketing department and the bean counters – what the cost per unit limit is, what the required production rate is, what materials they have to work with are etc – all decisions any production engineer has to wrestle with and the spec will dictate the materials used and production methods used. Other constraints like what and where their expertise lies, what the capabilities of their suppliers is. Like any engineered product you build to a spec. The spec is a compromise between cost, quality and other parameters. If you want to build the lightest AND strongest frame out there then it is going to be more expensive, if you are prepared to compromise on strength or weight then you compromise and reduce costs. Every company will have their own set of specifications based upon their target audience. Its no different to any other product or any other bike made from any other material.
The challenge with Carbon lay up is control over the wall thickness of the frame especially around frame intersections and junctions. If you cut open a carbon frame you’d find the inner surface will vary alot in terms of wall thickness, and your frame is only going to be as strong as its weakest point so your manufacturing processes and the control you have over the wall thickness is going to dictate the weight of your frame – if you want alot of control over the consistency of the wall thickness then you have to choose the appropriate product method, which will most likely be more expensive.
My point is that bike companies put on a significant premium on CF frames because they can get away with it – market pricing. Metal frames have come down in price since they went out to Taiwan for production to take advantage of cheaper production costs, CF bikes are getting to the same point but the price point is holding because why would you drop the price of something unless you had to? Same in Golf, same with sports cars etc. Bikes are no different. That is why companies like YT Industries can sell complete bikes for as much as a boutique brand frame – they command less of a premium for the frame, get big discounts for bulk buying the components and knock out great bikes for less. The boutique brand frame might or might not be any better – who knows? i’m not sure how you’d even test it. But it’s classic marketing.