So we’ve been experimenting with a new process of laser engraving here at Purely Custom that has raised some eyebrows. It’s a laser engraving method known as Black Engraving and it’s nothing short of…Wow! We snuck an image of this technique into an earlier blog and people started asking for it. By the way, that’s a good way to cause trouble with your co-workers when you let people in on something you know everyone is going to want before the business side is all worked out. In my defense, when something this cool comes along, you just can’t wait to share. So Yaron is one of our first customers to accessorize his ride with this new style and he was nice enough to share some pictures of how the caps looked on his bikes.

It may be hard to see but the engraving actually fills into the recess of the screw for a clean look. This new process is impressive and although it takes a little longer than traditional processes, the result is worth the wait.

Basics of Laser Engraving

Obviously this process of laser engraving involves using lasers to engrave an object and for Purely Custom that is quite often bicycle accessories, but can include trailer hitches, motorcycle parts, awards, and…trust me, this list could get pretty extensive. Lasers typically strip the surface and remove material; this ablation method is quite common and capable of your traditional YAG laser. New technology comes along, new formulas and ideas and all of a sudden Purely Custom is talking about Black Engraving and although the process is extensive, most cyclists collectively agree, “I don’t care how you do it, that’s one amazing headset cap.”

Black Engraving Simplified

It was only a few years back that we would engrave an object like a headset cap and then fill the gaps with black paint. The paint would fill the recesses and the rest would be washed away. It sounds simple but only 7 out of 10 caps would come out acceptable and paint is paint and not as durable as an actual laser engraving. We could make some pretty nice headset caps with this technique, but we were still searching for a process that gave us better contrast, a more efficient process, and more room for creativity. Black Engraving is a multi-pass engraving process that bakes the “paint” or photopolymer into the material and makes it as strong as the anodized color. Burning the black into the cap does take a little longer, in fact 10 times longer than a traditional engraving as the laser needs to be run at a lower speed. The longer process is worth it when you see the final result.

Yes… We Can Engrave the Screw

You heard correct, Purely Custom can engrave the screw, a feat that is not as obvious or simple as it might sound. Many people thought it was pretty cool that we offered several different colors of anodized screws, but this is a game changer. Engraving the bolt or screw does bring about one small problem, and that is determining exactly where the screw lands when it is tightened, which will be different for each bike.

Patterns of geometric designs work great for a pattern that travels across the screw; however something like a logo or writing risks misalignment. I did actually solve this problem, we just have everyone mail their bike to us, we tighten down the screw and headset cap, make an alignment mark and bam, solved it, everything lines up. So not a reasonable solution but I’m sure we’ll solve this with something that makes better sense.

The Process

Here’s an example of the process we would follow to create an intricate design with a few black widows on the headset cap.

We start with a red anodized aluminum headset cap, which we wash thoroughly with alcohol.

Stage two: We then airbrush on the polymer in a very thin and even coat.

Stage three: Using a slower setting, we burn the polymer into the cap wherever we would like it to be black. In this case, our spiders.

Stage four: We use our normal engraving setting to remove the rest of the red from the cap, except for the red hourglass patterns on the spiders, then we wash the remaining pigment away. Now it is time to stand back and admire one fine looking headset cap.

Not All Headset Caps Are Created Equal

I think it is important to talk about our headset caps and what sets us apart. We don’t use stickers or processes on our headset caps that peel or wash away. If you’re familiar with Purely Custom, you’re probably aware that we are part of a larger company known as Seastrom Manufacturing. Seastrom has been manufacturing quality standard and custom hardware since 1928. It’s a company that grew up in the military and aeronautical industry and later made it possible for Purely Custom to be an innovator in the cycling industry. So these headset caps you get from Purely Custom are aircraft grade aluminum made right here in Twin Falls, Idaho, USA with probably a little more quality than they really need, but that’s how we do everything around here. The screws are made just a few hours down the road from us in Boise and when they come in, we machine the head of the screw to match the radius of the cap for a smooth finish so everything meets our specifications.

Purely Custom Caps

The great thing about our caps lies in the fact that they really are custom in the purest sense of the word. You’re able to pick any color, design and engrave it just about any way you would like. If I could throw a headset cap straight, I could probably hit Tyler across the office, he’s our professional graphic designer who’s been handling the design and even the engraving of our caps for nearly ten years. Tyler can take your own design and make it a reality on a variety of bicycle accessories, including a headset cap. You submit your artwork, he’s the one working with the design and completing the laser engraving. Many custom designs can be ordered on our web site or we can take on a completely custom creation with your ideas or images.

Bike Shop Branding

Purely Custom produces hundreds of headset caps for independent bike dealers throughout the world. We just sent a few out to Japan, Canada, and Australia and some shops in the United Kingdom have more going out soon.

A custom headset cap is an excellent and classy way for a bike shop to display their name on every bike that goes out the door. My road bike I purchased this past fall from Cycle Therapy proudly displays their logo in green, tying in with the subtle green accents of the bike.

That cap looks great and they’re getting plenty of free advertising every time I show somebody my new road bike. Purely Custom has created several headset caps for bike shops, large cycling races like the sea Otter Classic and LOTOJA, and many other charity rides and large promotional events. Our production capabilities allow us to produce on a small scale, and if you find you need a couple thousand, we can certainly handle that as well.

How Do I Get One?

The headset cap is so easy to swap out that many people are creating several to display seasonally or pending events. We’ve made headset caps with Halloween designs, St. Patrick’s Day, and even Christmas. We’ve seen caps with motivational messages and some just embrace a clever design like this mosquito that belongs to Patrick Pedersen.

It’s time to get creative and personalize your bike with the cap that fits your personality. Purely Custom has the capabilities to create the perfect cap for your ride. The new patterned black engraving caps will be added to the website soon and remember they come with the screw so we can engrave across both.

In the meantime, checkout all the headset caps on www.purelycustom.com and grab some ideas on how to personalize your ride.