
![]() |
Edward Lowton
Editor |
![]() ![]() |
Home> | Plant, Process & Control | >Bearings | >First recyclable plastic bicycle frame made by igus |
First recyclable plastic bicycle frame made by igus
17 October 2024
Motion plastics specialist igus supplies the first injection-moulded bike frame made of composite material for e-bike manufacturer Advanced Bikes

FIRST IGUS launched the RCYL Bike, a bicycle made from recycled fishing nets. Now the company is setting the next milestone for sustainable mobility: a company first, it has developed an injection moulded bicycle frame made of recyclable composite material for the e-bike manufacturer Advanced Bikes.
To help drive the transformation to a circular economy, e-bike manufacturer Advanced Bikes is relying on igus for their future frame production. The companies have worked together to develop a sustainable, composite material bicycle frame for use in the new Reco Urban trekking e-bike. "Advanced's aim was to produce a frame from a composite material with 100% recyclable plastic using injection moulding," said Matthew Aldridge, managing director at igus UK."Since we have been developing components such as plain bearings, rod ends, and gears for the bicycle industry for over 30 years, we immediately took on the challenge of supporting Advanced in the bicycle frame design and taking over development, tooling and injection moulding."
New frame protects the environment
To ensure that the frame has sufficient strength, stiffness and low weight, igus uses a composite material in granulate form, consisting of high-performance plastics and carbon fibres. It also designed and made a multi-part injection moulding tool for the complex geometry of the bicycle frame within a few weeks. The result: a 3.3kg lightweight bicycle frame injected moulded in a single part – no welds, corrosion-resistant, durable and tested. igus is also able to regranulate end-of-life frames via its own "chainge" recycling programme, recycling the material.
Lubrication-free, high-performance plastic components
igus currently produces bicycle frames using two different processes In injection moulding, both components and frames are produced in one piece. Frames are also manufactured using rotationa moulding, such as for the RCYL bike. But it's not just about bicycle frames. igus has huge knowledge in plastics processing and this product development experience are now being used for new bicycle components - from wheels to cranks, from handlebars to planetary gears. Large and small volume production can therefore be carried out cost-effectively. In addition, these high-performance plastic components are lighter, lubrication-free and corrosion-free. Users can reach for the high-pressure cleaner because no lubricant is washed out and nothing can rust.
Maximum safety due to numerous test attempts
igus tests all components extensively before use. "We will test the first injection-moulded bike frames with computed tomography for problems such as air pockets in the composite material and carry out all relevant frame tests in our laboratory," Aldridge continued. Customers receive a 30-year warranty from Advanced Bikes. For maximum safety, igus uses a variety of test methods. "These are based on standard tests, for example by the EFBE (specialist bicycle standards agency) and the TÜV," says Aldridge. igus also conducts its own test procedures, including the use of a climate chamber, the data from which can be used to make precise statements about the service life of igus materials under different environmental conditions.
For more information:
Tel: 01604 677240
- Real twister
- Bearing and cable products
- Workflow system provides efficiency and productivity savings
- Press fitting tool
- Bearing material: Performance boosted
- Strain relief for tough environments
- Calculates service life of 3D-printed plain bearings
- Cable management: Less is more approach
- Structural tribo-filaments for 3D printing
- Bevel gears for lubrication-free motion