Igus develops recyclable plastic bicycle frame

Following the RCYL Bike, a bicycle made from 50 percent recycled fishing nets, Igus has developed a bicycle frame made from recyclable composite material for the German e-bike manufacturer Advanced Bikes for the first time, which is manufactured using the injection molding process. The expertise in plastics processing and the experience gained with the RCYL bike are being incorporated into the development of both the frame and new bicycle components made from high-performance plastics.

In 2023, more e-bikes than classic bikes were sold in Germany for the first time. The reason for this is not least the growing awareness of environmental protection. The problem: 90 percent of today's bicycle frames are made of aluminum or carbon, are produced in very energy-intensive processes and end up in huge bicycle landfills at the end of their service life. In order to drive forward the transformation to a circular economy, e-bike manufacturer Advanced Bikes is relying on Igus for its future frame production. Together, the companies have now developed a sustainable bicycle frame made of composite material, which is to be used in the new Reco Urban trekking e-bike.

"Advanced's requirement was to manufacture a frame from a composite material with 100 percent recyclable plastic using the injection molding process," recalls Jan Philipp Hollmann, Head of Bike Components at Igus. "As we have been developing and producing components such as bearings, rod ends, gears and guide rails for the bicycle industry for over 30 years, we immediately accepted the challenge of supporting Advanced with the design of the bicycle frame and taking on the development, toolmaking and injection molding."

New frame protects the environment

To ensure that the frame has sufficient strength, rigidity and low weight, Igus uses a composite material in granulate form, consisting of high-performance plastics and carbon fibers. In addition, Igus produced a multi-part injection mold for the complex geometry of the bicycle frame within a few weeks. The result: a 3.3 kg lightweight, one-piece injection-molded bicycle frame - without weld seams, corrosion-resistant, durable and externally tested. Production in Germany enables short delivery routes and just-in-time production in line with demand. Igus is also able to regranulate used frames via its own "Chainge" recycling program in order to return the material to the material cycle. "In the future, we also want to have other recyclable bicycle components such as luggage racks, rims, spokes and seat posts manufactured using the injection molding process," explains Helge von Fugler, founder and Managing Director of Advanced. "This is the only way to make a completely recyclable e-bike a reality."

Components made from lubrication-free high-performance plastics

Igus currently produces bicycle frames in two different processes at its headquarters in Cologne. In injection molding, both modular and frames are produced in one piece. In addition, frames are manufactured using the rotomolding process - for example for the company's own RCYL bike. But Igus is not limited to bicycle frames either. The know-how in plastics processing and the new development experience are now also being incorporated into new bicycle components - from wheels, cranks and handlebars to planetary gears. Large and small series production can thus be realized cost-effectively - and "made in Cologne". In addition, the components made of high-performance plastic are lighter, lubrication-free and corrosion-free. Users can therefore easily reach for the high-pressure cleaner, as no lubricant is rinsed out and nothing can rust.

Maximum safety thanks to numerous test trials

Before they are used, Igus tests all components extensively. 135 trillion test cycles and 15,000 tests take place every year in the 4,000 square meter test laboratory in Cologne. 250 square meters of this are used for the test benches alone, on which all bicycle components are tested. This also applies to the new Reco frame. Hollmann: "We will test the first injection-molded bicycle frames with computer tomography for possible problems such as air inclusions in the composite material and carry out all relevant frame tests in our test laboratory." Customers receive a 30-year guarantee from Advanced. Igus therefore relies on a large number of test procedures to ensure maximum safety. "These are based on standard tests, for example from the EFBE and TÜV," emphasizes Hollmann. "We also carry out our own test procedures - for example in our climate chamber." The data obtained can be used to make precise statements about the service life of the materials under different environmental conditions.

From design to the finished product

"With our bicycle components made of high-performance plastic, we offer the bicycle industry access to a completely new technology," says Hollmann. "We also appeal to OE manufacturers who want to innovatively implement their own ideas and designs with us." By using plastic, developers can rethink design and geometry. And at Igus, they also get everything from a single source: from design to research and development, toolmaking, compounding, testing and production through to recycling. Thanks to just-in-time production, igus is able to deliver quickly and customers' storage capacities can be reduced. Production to order makes business more predictable and profitable.