It is estimated that around 15 million bicycles end up in landfill every year. Many also end up at the bottom of canals all over the world, leading to a considerable waste problem.Initiatives to make bicycles more durable, easier to repair, and recyclable are key to addressing the issue.
Now, Germany-based manufacturer of technical products made of high-performance plastics Igus has developed an electric bicycle frame made entirely from recyclable plastics.
The vast majority of today’s bicycle frames are made of steel, aluminium, or carbon-fibre. These materials are produced using energy-intensive processes, are costly, and are heavier than plastic, except for carbon-fibre.
Igus has partnered with German e-bike manufacturer Advanced Bikes to introduce recyclable plastic an alternative material. The company uses a composite granulate consisting of high-performance plastics and carbon fibres to ensure sufficient strength, rigidity, and low weight. It also designed a multi-part injection moulding tool for the complex geometry of the bicycle frame. The result is a single piece injection-moulded bicycle frame weighing only 3.3 kg. Because it is made of plastic, the frame has no weld seams and is corrosion-resistant.
The composite plastic bicycle frame is used in the new Reco Urban trekking e-bike from Advanced Bikes.
“Advanced’s aim was to produce an injection moulded composite frame with 100 per cent recyclable plastic,” said Jan Philipp Hollmann, head of bike components at Igus. “As we have been developing and producing components such as plain bearings, rod ends, gears and spherical bearings 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 production.”
The manufacturer recycles the bicycle frames through its own recycling programme, called ‘chainge’. The platform accepts PA, POM, PBT, PEEK, PE, and PP, and also acts as a marketplace for buying or selling recyclates.
Going forward, Advanced Bikes wants to integrate other injected moulded recyclable plastics in its portfolio, including pannier racks, rims, handlebars, and seat posts.
“This is the only way to make a fully recyclable e-bike a reality,” concluded Helge von Fugler, founder and managing director of Advanced Bikes.