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Kalex

Kalex Engineering is a specialty engineering firm based in Bobingen, , renowned for designing, manufacturing, and supplying high-performance chassis and components for motorcycles, particularly in the Moto2 class of the FIM . Founded by Alexander Baumgärtel and his partners, the company entered the Moto2 category in 2010, quickly establishing itself as a leader through innovative aluminum frame designs that emphasize flexibility and tire contact optimization. Since its debut victory in the 2011 Moto2 Riders' Championship with Stefan Bradl, Kalex has dominated the category, securing 13 consecutive Constructors' Championships from 2013 to 2025 and contributing to 13 Riders' titles in the same period, including Diogo Moreira's 2025 title. By the end of the 2024 season, Kalex chassis had amassed 187 wins, including 11 victories that year alone, outpacing rivals like Boscoscuro to claim the Constructors' title with 437 points; by the end of 2025, the total exceeded 200 wins. The company's success stems from a small team of about nine engineers who utilize advanced CAD modeling for and adaptation to engines like the 765 introduced in 2019. In addition to racing, Kalex offers aftermarket parts such as clamps, swingarms, and carbon components for superbikes and custom applications, available through their online shop, extending World Championship-derived technology to enthusiasts. In 2025, Kalex clinched its 13th Constructors' Championship at the and confirmed its Riders' title with Moreira at the finale on November 16, underscoring its enduring influence despite increasing competition in the intermediate class.

Company History

Founding and Early Years

Kalex Engineering was established in 2008 in Bobingen, , , as KALEX engineering GbR by engineers Klaus Hirsekorn and Alex Baumgärtel. The company name derives from a combination of the founders' surnames, reflecting their collaborative origins in motorsport engineering. The concept originated in 2004 following a training session, with construction of their first prototype, the , beginning in 2005 while the founders were still employed full-time elsewhere. Hirsekorn contributed extensive experience from motorsports, while Baumgärtel brought expertise from the automotive sector, having worked at Holzer Motorsport on drivetrains and suspension systems for cars. Despite their primary backgrounds in car racing, both founders shared a deep passion for motorcycles, which drove the venture. From its inception, focused on designing and producing high-performance , emphasizing tailored for competitive racing. This dedication to quality and innovation stemmed directly from the founders' combined 30 years of know-how. The company's early competitive breakthrough occurred in 2008, when rider Damian Cudlin secured Kalex's first race victory at the Schleiz circuit in . This success highlighted the potential of their initial designs and marked Kalex's entry into circuits.

Expansion into Professional Racing

Following its founding in , Kalex Engineering entered a preparation phase in 2009, transitioning from a two-person operation led by founders Klaus Hirsekorn and Alex Baumgärtel to broader development efforts, ultimately expanding to a nine-person team by 2020. This growth was rooted in the Holzer Group's established success in , particularly through Hirsekorn's prior experience in racing, which provided foundational expertise in chassis design and . The company's early during this period involved prototyping and testing, building on initial successes like the 2008 race victory of the KALEX AV1 at Schleiz. Kalex made its entry into the Moto2 class in 2010 through a key partnership with Pons Racing, supplying chassis for the new 600cc four-stroke category that replaced the 250cc two-stroke machines. The prototype was unveiled in November 2009 at the , with testing conducted by rider Axel Pons ahead of the 2010 season debut. This collaboration marked Kalex's initial foray into international racing, aligning with the class restructuring aimed at cost control and standardization via controlled engines. The transition from the 250cc era to Moto2 presented early challenges for , including adapting to the new specifications and requirements amid a competitive field dominated by established manufacturers like Moriwaki and Suter. In its debut season, the Pons team struggled, scoring only 2 points as teams grappled with the shift to four-stroke power delivery and revised . These hurdles prompted rapid iterations in and setup, leveraging feedback from the single-supplier to refine handling and performance. By 2011, Kalex achieved significant milestones, including its first at the Qatar season opener secured by Stefan Bradl for Kiefer Racing, followed by multiple podium finishes that demonstrated improved competitiveness. These results, including Bradl's season-capping riders' championship title, positioned Kalex as a contender in Moto2 and laid the groundwork for sustained involvement in the series.

Products and Technology

Chassis and Key Components

The primary product of Kalex Engineering is the Moto2 , a twin-beam aluminum CNC-machined from blocks of solid 5083 aluminum to ensure precise control over material properties and flex characteristics. This construction method preserves the 's , avoiding alterations from heat or pressure that could affect stiffness. The features tapered side beams to promote controlled rearward flex, enhancing tracking during cornering, while carbon fiber sheathing on the beams provides additional under braking. Key components include the aluminum , also CNC-machined for adjustable and optimized rigidity to improve handling and . Triple clamps are designed with variable stiffness between the upper and lower units to fine-tune front-end feel and response, complemented by multi-adjustable , , and settings. Linkage systems offer alternative rear configurations for adaptability, and carbon fiber elements, such as bodywork, contribute to overall weight reduction and aerodynamic efficiency. Kalex's design philosophy emphasizes lightweight construction with intentional flexibility—such as aluminum sections as thin as 1.2 mm at certain points—for heightened responsiveness and rider feedback, while prioritizing forgiveness in dynamics to maintain stability across varied track conditions. This approach contrasts with more rigid predecessors, providing a broader setup window that allows teams to achieve competitive performance more readily. The demonstrates strong adaptability to changes, including the 765 cc triple introduced in , without compromising its core handling traits. Since its debut in the 2010 Moto2 class, Kalex components have evolved through iterative refinements, transitioning from initial designs to versions that offer superior ease of setup compared to earlier dominant frames like those from Suter, contributing to widespread adoption in the championship.

Development and Manufacturing Processes

Kalex Engineering, headquartered in Bobingen, , utilizes over 30 years of specialized know-how in development and manufacturing, drawing from more than 50 years of collective experience across disciplines including and rallye to inform its motorcycle chassis innovations. This foundation enables and iterative refinement, allowing the company to adapt quickly to evolving racing requirements while maintaining precision in high-stakes environments. The development process begins with advanced digital tools, including CAD software such as Unigraphics and NX-Siemens, which facilitate comprehensive and styling. These designs undergo rigorous (FEM) analyses and flow-simulations to evaluate structural integrity, stress distribution, and aerodynamic performance, ensuring components withstand extreme loads encountered in professional . Extensive functionality tests and geometrical verifications further validate prototypes before production. Manufacturing at Kalex emphasizes CNC machining with state-of-the-art equipment to mill intricate components from solid aluminum blocks, achieving the sub-millimeter tolerances essential for Moto2 applications. This subtractive process, preferred over forming methods like heating and pressing, preserves the alloy's inherent strength and fatigue resistance. The Bobingen facility's integrated workflow supports seamless transitions from simulation to fabrication, incorporating and for final construction. A key example of applied innovation occurred with the 2019 Moto2 engine transition from to 765 units, where Kalex integrated DTM-derived engineering principles to customize and mounting points, enabling sustained competitiveness and multiple race wins that season.

Moto2 Involvement

Entry and Initial Successes

Kalex Engineering entered the Moto2 in 2010, coinciding with the class's as a replacement for the 250cc two-stroke category, providing to the Pons Racing team as one of the earliest alternatives to the dominant Suter supplier. The new regulations mandated a spec 600cc engine, requiring rapid adaptation from the outgoing two-stroke era, and Kalex's debut was unveiled and tested in late 2009 ahead of the 2010 season launch. Initial challenges for included financial constraints in the phase, where the small outfit balanced designing, testing, and while relying on freelance work to sustain operations, alongside the technical demands of integrating the controlled powerplant into a competitive . Early rider feedback highlighted the frame's advantages over rivals like Suter, noting its more forgiving handling and ease of riding, which contributed to consistent performance despite the in the spec-engine environment. A breakthrough came in 2011 when Stefan Bradl, riding for Viessmann Kiefer Racing on a Kalex, secured the Riders' Championship—the first world title for the manufacturer—with 274 points from four victories, including the season-opening win in . Bradl's success, marked by 11 podium finishes, validated Kalex's design philosophy and elevated its profile in the paddock. By 2012, Bradl's championship momentum prompted increased team adoptions, with five outfits switching to for the season, expanding its presence beyond the initial single-team entry. This growth yielded multiple results, such as the five achieved by the , demonstrating improved reliability and competitiveness that positioned Kalex for subsequent dominance, including a constructors' title streak beginning in 2013.

Constructors' Championship Results

Kalex Engineering has dominated the Moto2 Constructors' Championship since its debut in the class, securing an unbroken streak of 13 consecutive titles from 2013 to 2025. This run underscores the manufacturer's technical superiority and widespread adoption across the grid. Among these victories, Kalex won every race in 2016, 2020, and 2021. Key milestones highlight Kalex's escalating success. By the end of , Kalex had accumulated 70 race wins in Moto2, with a points tally of 427 that year—161 ahead of second-placed KTM. This dominance intensified over time; by 2019, the total reached 85 victories, bolstered by a remarkable streak of consecutive race wins that ended at the 2017 Misano . Further, in 2021, Kalex clinched the title with a commanding 450 points, outpacing by 251. By 2023, the victory count had risen to 114, reflecting sustained performance amid evolving regulations. Annual highlights illustrate pivotal moments in this era. In 2013, Kalex claimed its inaugural Constructors' title with 392 points, overtaking established rival Suter (297 points) through 13 race wins out of 17. The 2019 season tested adaptability following the switch to three-cylinder engines, yet Kalex maintained its lead with 14 victories and a points haul that secured the crown ahead of KTM. In 2024, Kalex defended its title against intensifying competition from Boscoscuro, finishing as the top constructor with 437 points and 11 wins, aided by teams like Flexbox HP40. The streak continued in 2025, with Kalex clinching its 13th title at the . Several factors underpin 's prolonged success. By 2015, the had gained favor with the majority of Moto2 teams due to its superior reliability, forgiving handling, and ease of setup, enabling consistent top finishes across diverse track conditions. These attributes not only facilitated high adoption rates—peaking at over 70% of —but also minimized mechanical failures, allowing Kalex-equipped riders to capture the bulk of podiums and points in subsequent years.

Riders' Championship Achievements

Kalex chassis powered 13 Moto2 Riders' World Championship titles between 2011 and 2025, establishing the German manufacturer as a cornerstone of success in the intermediate class. This run began with Stefan Bradl's inaugural victory in the category's second year and continued through a period of unchallenged dominance, with only the 2012 season (won on a Suter by ) and the 2024 season (won on a Boscoscuro by ) interrupting the sequence. Riders on Kalex machines benefited from the 's reputation for superior balance and adaptability, contributing to consistent top performances across diverse track conditions. The breakthrough came in 2011 when Stefan Bradl, riding for Viessmann Kiefer Racing, clinched the title with 274 points from 4 race wins, including early-season victories at , , and Catalunya that built an insurmountable lead. Bradl's campaign highlighted the Kalex's debut potential, as he navigated a competitive field to secure the championship in the final round at despite a late surge from . This success marked Kalex's entry into elite status, with Bradl praising the chassis's stability in high-speed corners during post-race interviews. Subsequent years saw a string of champions leveraging the Kalex's refined geometry for enhanced handling. Pol Espargaró (2013, Tuenti Racing) and Tito Rabat (2014, Marc VDS Racing Team, amassing 346 points through 6 victories and demonstrating the chassis's edge in braking zones and mid-corner speed) continued the success. Johann Zarco stands out as the only multiple winner in this era, dominating back-to-back titles for Ajo Motorsport in 2015 (352 points, a then-record tally with 8 wins) and 2016 (230 points, 6 wins), where he credited the Kalex's forgiving setup for maintaining podium consistency even in suboptimal conditions. Other key victors included Franco Morbidelli (2017, EG 0,0 Marc VDS), Francesco Bagnaia (2018, Sky Racing Team VR46), Álex Márquez (2019, EG 0,0 Marc VDS with 262 points and 5 wins), Enea Bastianini (2020, Italtrans Racing Team with 205 points from 3 wins amid a shortened season), Remy Gardner (2021, Petronas Sprinta Racing), and Augusto Fernández (2022, Flexbox HP40). The 2023 season culminated Kalex's riders' title streak with Pedro Acosta's emphatic victory for KTM Ajo, wrapping up the championship two races early after a second-place finish at the . Acosta tallied 320 points with 7 wins, underscoring the chassis's role in his rapid adaptation from Moto3 and aggressive riding style that yielded 14 podiums. In 2025, secured the title for Italtrans Racing Team, clinching it at the with 287 points from 4 wins, becoming the first Riders' World Champion and extending Kalex's legacy. Riders frequently attributed Kalex's legacy to its advantages in handling and straight-line speed, describing the chassis as more forgiving and easier to tune than predecessors like the Suter, which allowed for quicker times without excessive risk. This was exemplified in , when Kalex machines claimed all 18 positions across the season's races, reflecting their qualifying prowess under varying and track setups. Such attributes not only facilitated individual triumphs but also amplified Kalex's constructors' dominance, enabling riders to push limits while maintaining reliability over grueling 18-round campaigns.

Other Racing and Applications

Superbike and Additional Series

Kalex Engineering expanded its presence beyond the Moto2 World Championship into the (WorldSBK) starting in 2017, supplying specialized components such as swingarms, triple clamps, and frontend kits to professional teams. These parts, machined from high-grade aluminum for optimal strength-to-weight ratios, offer significant performance advantages, including swingarms that are approximately 20% lighter than standard production versions while maintaining rigidity for better grip and stability. Teams like have integrated Kalex components to refine handling and reduce lap times, with early collaborations yielding podium finishes in the series. For instance, BMW adopted the Kalex from 2022 to 2024, which riders noted improved frontend feel and overall race pace, contributing to competitive edges in high-stakes rounds. BMW discontinued the Kalex for the 2025 season, opting for in-house production. This from Moto2 design emphasizes tailored for superbike demands, such as adjustable for varying track conditions. In the British GP2 class, introduced as a support series to the British Supersport Championship in 2018, Kalex chassis—often adapted from former Moto2 machines—have dominated following the Moto2 category's engine transition to units, enhancing class competitiveness with superior and suspension integration. Josh Owens claimed the inaugural 2018 title aboard an RS Racing Kalex, securing multiple overall race wins and three podiums that highlighted the bike's reliability and speed. The series' success continued with Kalex machinery, as evidenced by Jack Scott's 2022 championship victory for RS Racing, where he achieved 14 race wins and an additional , including an outright supersport class triumph at Thruxton, underscoring the chassis's adaptability post-Moto2 engine changes. Kalex also entered the Spanish Flattrack Championship in 2017 as a key supplier, delivering custom components like lightweight frames and suspension elements optimized for the discipline's high-torque, dirt-oval demands. These parts have supported flat-track riders in achieving competitive results, leveraging Kalex's expertise in durable, high-performance aluminum fabrication to withstand the series' abrasive conditions and contribute to event wins.

Custom Solutions and Commercial Products

Kalex Engineering provides services for non-standard and street motorcycles, emphasizing individualized over mass-produced components. Their process encompasses a full cycle of , , , , , , and testing to ensure precise fit, optimal , and elevated standards. Guided by the "Because standard is not 'worx'", the company utilizes advanced tools such as CAD for and FEM for to develop tailored and components that meet specific rider or vehicle requirements. Examples of custom solutions include specialized swingarms and triple clamps adapted for models in and flattrack applications, as well as suspension rebuilding kits for R1 street bikes. These services cater to enthusiasts seeking performance enhancements without adhering to specifications, allowing for adaptations like grip upgrades or geometry optimizations suited to individual riding styles. In addition to custom engineering, Kalex operates an online shop that democratizes access to racing-derived parts, offering items such as triple clamps, carbon fiber components, swingarms, and linkage systems directly to private teams and hobbyists. Launched to extend World Championship-proven technology beyond professional circuits, the shop enables users to incorporate high-precision elements into their own builds, fostering innovation in personal projects. The company's commercial expansion includes the sale of Moto2-inspired parts adapted for superbike and applications, such as lightweight upgrades that reduce weight by approximately 20% compared to stock versions through upside-down welded and milled components. These products feature adjustable positions in 1mm increments and with standard swingarms, providing semi-professional and hobbyist riders with enhanced grip and stability without the full complexity of race-spec hardware. Frontend upgrades like the Frontgrip-Miracle further allow for tunable offset and via shaft adjustments, prioritizing precision and adaptability for non-competitive use. Global shipping supports this retail model, making these components accessible to international customers.

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