For the first time, Igus has developed a bicycle frame made of recyclable composite material for the German e-bike manufacturer Advanced Bikes, which is manufactured using the injection molding process. The decades of expertise in plastic processing and the experience with the RCYL Bike flow into the development of the frame as well as new bicycle components made of high-performance plastics.

In 2023, more e-bikes than classic bicycles 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 using very energy-intensive processes and end up in huge bicycle landfills at the end of their service life. In order to drive the transformation to a circular economy, the 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 trekking e-bike Reco Urban. "Advanced's aim was to produce a frame from a composite material with 100 percent recyclable plastic using an injection molding process," recalls 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 guide rails for the bicycle industry for over 30 years, we immediately accepted the challenge of supporting Advanced in the design of the bicycle frame and taking on both development and toolmaking and injection molding."

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 manufactured a multi-part injection molding tool for the complex geometry of the bicycle frame within a few weeks. The result: a 3.3 kg lightweight bicycle frame molded from a single part - without weld seams, corrosion-resistant, durable and externally tested. Production in Germany enables short delivery routes and just-in-time production based on demand. igus is also able to regranulate used frames using its own "chainge" recycling program in order to return the material to the recycling 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 a completely recyclable e-bike can become a reality."