igus Introduces First Injection Molded Engineering Plastic Bicycle Frame for Advanced Bikes

igus Continues to Expand Its Bicycle Components Business with First Injection Molded Engineering Plastic Bicycle Frame for Advanced Bikes

After the RCYL, a bicycle made from 50 percent recycled fishing nets, igus has achieved another milestone in the field of sustainable mobility: the sports plastics company has developed a bicycle frame made from recyclable engineering plastics for the German e-bike manufacturer Advanced Bikes, which is made using injection molding. The frame, along with other new bicycle components made from high-performance engineering plastics, is the result of decades of igus' engineering plastics know-how and RCYL bicycle development experience.

In recent years, people have become more environmentally conscious. However, 90% of today's bicycle frames are made of steel, aluminum or carbon fiber, and the production process is so energy intensive that they end up in huge bicycle landfills at the end of their useful life. In an effort to make the transition to a circular economy, e-bike maker Advanced Bikes commissioned igus to produce bike frames for them. As a result, the two companies collaborated to develop a sustainable composite plastic bike frame that will be used on the new Reco Urban off-road e-bike. “Advanced's approach was to produce an injection-molded composite frame made from 100 percent recyclable plastic.” Jan Philipp Hollmann, Head of Bicycle Components at igus, recalls, “We have been developing and producing components such as plain bearings, rod ends, gears and self-aligning bearings for the bicycle industry for more than 30 years, and we were very confident in taking on the task of helping Advanced to plan the bicycle frame and to take on the development of the frame, mold making and production.”

The new frame is environmentally friendly

To ensure that the frame has the strength and stiffness it needs and is lightweight, igus used a granular composite material that blends high-performance engineering plastics with carbon fiber. In addition, igus developed a special composite molding system in a matter of weeks for a bicycle frame with complex geometry. The end product is a lightweight (3.3kg) one-shot injection-molded bicycle frame that is weld-free, corrosion-resistant, durable and externally tested. The frame is made in Germany for fast delivery and can be produced on demand and on schedule. At the end of the frame's service life, the frame can also be recycled through igus' chainge take-back program to reuse the material. “In the future, we would also like to use the injection molding process to produce other recyclable bicycle components, such as racks, rims, handlebars and seatposts.” Helge von Fugler, founder and managing director of Advanced, explains, “This is the only way to accomplish a fully recyclable e-bike.”

The new bicycle frame is simple (3.3 kg), recyclable and made in one piece using an injection molding process. To ensure that the frame has the strength and stiffness

strength and stiffness, as well as its low weight, igus uses a granular composite material that is a blend of high-performance engineering plastics and carbon fibers. (Source: igus)

Components made of non-slip high-performance engineering plastics

Currently, igus uses two different processes for the production of its bicycle frames at its headquarters in Cologne. One is the injection molding process, which is used for both modular and single-piece frames. In addition, there are also frames made using the rotomolding process, such as the frames for igus' own RCYL bikes. Of course, igus does not only supply bicycle frames. Thanks to its in-depth knowledge of plastics processing and its new development experience, igus has also developed many other bicycle components, such as wheels, cranks, handlebars and planetary gears. All of these products are now capable of low-cost production in large or small batches. In addition, these high-performance engineering plastics components are easy to use, non-slip and corrosion-resistant. As a result, users can utilize the pressure washer with confidence: there is no need to worry about rinsing off the lubricant, and there is no rust anywhere.

Extensive testing ensures high reliability

Before going on sale, igus conducts extensive tests on all components. In the 4.000 square meter igus test laboratory, 135 trillion test cycles and 15.000 tests are performed every year. The bicycle test bench alone covers 250 square meters, on which all components such as wheels, handlebars and cranks are tested. The new Reco frame is no exception, says Hollmann: “We will be using computed tomography (high-tech imaging) to look for potential shortcomings in the first injection-molded bicycle frames (e.g. air holes in the composite material), and we will carry out all the relevant frame tests in the test lab.” Customers are able to take advantage of a 30-year warranty supplied by Advanced. To ensure maximum safety, igus conducts a number of tests on its products. “These are based on standardized tests, such as those of EFBE and TüV.” Hollmann emphasizes, “We also have our own tests, for example in our climate chamber.” Based on the data from these tests, it is possible to accurately predict the service life of igus materials under different environmental conditions.

As part of its transition to a circular economy, e-bike manufacturer Advanced Bikes has commissioned igus to produce its bicycle frames.

(Left: Helge von Fugler, founder and managing director of Advanced; right: Jan Philipp Hollmann, head of bicycle components at igus).

(Source: igus).

One-stop shop for the entire process: from planning to final product

“By choosing bicycle components made from high-performance engineering plastics, we are offering the bicycle industry a completely new skill set.” says Hollmann. In this way, we also want to attract interested OEMs to work with us to turn their ideas into reality,” says Hollmann.” By using engineering plastics, developers are able to think about product planning and geometry in a whole new way. igus is able to offer a one-stop shop for the entire process: from planning to development, mold making, mixing, testing, and production, right through to take-back of the product. Just-in-time production lines mean that igus is able to deliver quickly, which saves storage space for the customer. The made-to-order approach increases the predictability and profitability of the business.