Abstract: Processes, systems, and methods described herein can be used for manufacturing reinforced carbon fiber structures. For example, processes can include forming a plurality of foam substructures. The foam substructures can be made of heat expanding foam that further expands when heated to a first threshold temperature. Processes can also include positioning carbon fiber on at least a portion of surfaces of the foam substructures, assembling the plurality of foam substructures with the carbon fiber into a superstructure, wrapping an outer surface of the superstructure with additional carbon fiber to form a wrapped superstructure, and curing the wrapped superstructure within a mold to form a reinforced carbon fiber structure. The reinforced carbon fiber structures can include internal truss structures within the foam. The reinforced carbon fiber structures can be used to form reinforced carbon fiber bicycle frame components.