If you’re into titanium frames, then it’s possible you’ve heard the name Ari Emmett before. If you haven’t, you’ve almost definitely seen his work. In the past 15 years or so, Ari has been involved with some of the biggest names in titanium, like DEAN, Merlin, and, most recently, Mosaic. Now, he’s starting his own venture, AE MFG (Ari Emmett Manufacturing), leveraging his experience, craftsmanship, and passion to produce 100% custom titanium frames on a small scale with purposefully limited production.
Ari started as an intern at DEAN Titanium, sweeping floors and doing finish/quality control work. Ultimately, he got hired full-time, but after a couple of years, the brand was shutting down. Ari purchased DEAN and turned it into DEAN Cycleworks, and started trying new things, including full-suspension designs and more complex swoopy frames that were popular at the time. Eventually, Ari and his then business partner purchased Merlin Metal Works as well, and he became the majority owner of the Janus Cycle Group.
In both instances, Ari helped resurrect and breathe new life into these brands while continuing to hone his craft as a welder, fabricator, and frame designer. Ultimately, Ari passed the torch and sold the Janus Cycle group — including DEAN and Merlin — in 2021. At that point, he moved on to Mosaic Bespoke Bicycles, where, alongside the company owner, Aaron Barcheck, he was the lead welder of some of the most lustworthy frames out there. At Mosaic, Ari says he was welding a little over five frames a day and over 500 in his year and a half tenure.
After Mosaic, Ari took a little time off, a sabbatical, if you will, and did some other things. Eventually, he realized something was missing, and that thing was making bikes. So, he started his latest venture, AE MFG, which officially opened earlier this year. This new business represents a radical new approach for Ari, with fully custom bikes and production limited to 20 frames in the first fiscal year. By keeping things small, Ari says, “the whole idea is to maintain a level of consistency and quality control that isn’t possible at higher volumes.”
At present, AE MFG is starting with two platforms, Road38 and Gravel50, and handcrafting 100% custom frames for each rider. Like any good custom bike, the process starts with a bike fit, either in person or through one of Ari’s network of fitters across the country. But beyond custom geometry, Ari tells me that he uses his extensive frame-building experience to choose the tubing diameters and thicknesses based on the person. In the end, “Each build is a bespoke masterpiece — tuned to your riding style, geometry preferences, and visual flair. No two are alike because no two riders are.”
The Road38 is a true road bike with all-road capability and clearance for tires up to 38c. The Gravel50 is a modern gravel bike with clearance for tires up to 50c. Both are made with premium, certified titanium tubing, renowned for its ride feel, comfort, and durability. Whether you go R38 or G50, the frames come with carbon ENVE forks, disc brake mounts, and riders can choose between internal and external cable routing and a range of finishes.
Ari is a welder and frame designer, so he lets other people work on those finishes. He utilizes renowned titanium finishers, Agave Finishworks and TiO2 Designs, to put the final touches on the frames. In total, Ari says the entire process takes 1 to 3 months, depending on the customer and how quickly they make decisions. The frames sell for $6,150, including the fork and headset, but final prices can vary depending on selected options. While that is by no means cheap, it is certainly competitive in the boutique, fully custom titanium frame market, where competitors’ frames often cost quite a bit more.
AE MFG has only just opened its doors, and the website is even still under construction, but Ari tells us that he has a couple of frames already in the queue. One of the first is going to one of his longest supporters, who has been with him since the DEAN days, and this will be the 7th frame he’s made for him.
Ari also tells us that he’s planning to attend and display his bikes at the Philly Bike Expo in March 2026. Until then, if you’re interested in your own custom titanium dream machine, AE MFG is taking orders now. You can find out more about Ari and the bikes or make inquiries through the AE MFG website, or check him on Instagram @ae_mfg_usa.
