Smart Molding International 2-2024

26 smart_molding international 2/2024 molding technologies igus develops first recyclable plastic bicycle frame igus continues to expand its bicycle component business and presents the first injection-moulded polymer bicycle frame for advanced bikes. A fter RCYL, a bicycle made from 50 per cent recycled fishing nets, igus is setting the next milestone for sustainable mobility: the motion plastics specialist has developed the first bicycle frame made from recy- clable plastic material for the German e-bike manufacturer Advanced Bikes, which is manufactured using injection moulding. Decades of expertise in plas - tics manufacturing and experience with the RCYL bike are channelled into the development of both the frame and new bicycle components made from high-performance plastics. In 2023, more e-bikes than traditional bikes were sold in Germany for the first time. One reason for this is the growing awareness of environmental concerns. The problem: 90 percent of today's bicycle frames are made of steel, aluminium or carbon-fibre and are produced using very energy-intensive processes, only to 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 their future frame production. Together, the companies have now developed a sustainable composite plastic bicycle frame, which is to be used in the new Reco Urban trekking e-bike. “Advanced's aimwas to produce an injection moulded composite frame with 100 per cent recyclable plastic,” 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 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, tool making and production.” 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 fibres. In addition, igus produced a multi-part injection moulding tool for the complex geometry of the bicycle frame within weeks. The In order to drive forward the transformation to a circular economy, e-bike manufacturer Advanced Bikes is relying on igus for future frame production (left: Helge von Fugler, founder and Managing Director of Advanced; right: Jan Philipp Hollmann, Head of Bike Components at igus)