As mentioned in our previous blog post, we recently had the opportunity to tour the factory of NITTO! While our last entry focused on the secret behind the strength of Nitto’s highly reliable products, this time we’d like to dive a little deeper: they were actually manufacturing drop handlebars right when we were visiting, so we want to share the production process with you!
Nitto handlebars and racks are made from the pipes shown in the photo above. Even within the term "handlebar," there are differences in pipe diameter between flat bar types (grip diameter: 22.2mm) and drop bar types (grip diameter: 23.8mm), and the clamp diameters (the section where the handlebar is fixed) also come in various sizes. We learned that they stock pipes with different inner diameters to bring out the characteristics specific to each material and model.
Here’s a little piece of trivia regarding their handlebars: many of the company vehicles Nitto uses to transport parts have the number "210" on their license plates, a wordplay on "Nitto." We love little details like this!
The photo above shows the NITTO Mod177 Noodle Bar, which arrived recently. Like this one, many old-school handlebars with a 26.0mm clamp diameter have a distinct "step" at the clamp section. Did you know about that? It isn't created by machining away material or using a pipe that is shaped that way from the start—it’s actually added on later. Curious how? Let’s dig into it!
Manufacturing a single drop handlebar requires about 1 meter of pipe, so they take 4-meter pipes and cut them into four equal pieces. At this stage, the pipe is just cut to the proper length with some grooves carved into it—it’s essentially in its raw state. The clamp section doesn't have that "step" yet.
They insert the short 26.0mm outer-diameter pipe shown in the left photo and set it in a press machine. You might assume they use adhesive or crush the metal to fix the pipe in place, but instead, they insert a rubber-like elastic elastomer rod into the pipe and expand it. This causes the inner pipe to expand slightly and lock into position. This method is called "bulge forming," and by increasing the thickness of the pipe at the clamp section, it improves strength while requiring fewer production steps.
Although the clamp section is finished, it’s still just a straight pipe. Now it’s time to shape it into a drop handlebar.
Using specialized equipment, they manually bend the straight pipes we just saw. Working in pairs, one person bends the "shoulder" of the handlebar, while the other bends the drop section to form the shape. It’s finally starting to look like the handlebars we see every day! This is how the iconic form of Nitto drop handlebars is created.
Once shaped, each handlebar is carefully polished by hand to bring out a high luster. The quality of the finish depends entirely on the skill of the craftsman. After all, handlebars are always in your field of vision while riding. It truly is artisanal work…
From there, the bars undergo even finer polishing and are wiped clean before being bagged and shipped to customers. Celebrating their 100th anniversary, Nitto has spent that century at the forefront of the bicycle industry, manufacturing countless handlebars, racks, and more. Each step, based on the craftsmanship accumulated since their founding, serves as the foundation of Nitto, and these products continue to be made using the latest equipment that has evolved over time. Furthermore, as mentioned in our previous blog, they subject their products to numerous rigorous safety tests—it is this comprehensive, uncompromising system built over 100 years that is reflected in every single one of their products.
