Smart Molding International 2-2024

27 www.smart-molding.com molding technologies result: a 3.3 kg lightweight, single piece injection-moulded bicycle frame − without weld seams, corrosion-resistant, durable and externally tested. Production in Germany also enables short logistic distances and just-in-time production aligned with demand. igus is able to regranulate end-of-life frames via its own “chainge” recycling programme in order to re-use the material. “In future, we also want to have other recyclable bicycle components such as pannier racks, rims, handlebars and seat posts manufactured using injection moulding,” explains Helge von Fugler, founder and Managing Director of Advanced. “This is the only way to make a fully 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 moulding, both modular and single-piece frames are produced. There are also frames that are manufactured using the rotomoulding process − for example for the company's own RCYL bike. But even for igus, it's not just about bicycle frames. The in-depth expertise in plastics processing and the new development experience are now also being channelled into new bicycle components − from wheels, cranks and handlebars to planetary gears. Large and small volume cost effective production is the reality − and “made in Cologne”. The high-performance plastic components are also lighter, and free from all lubrication and corrosion. Users can therefore reach for the high-pressure washer without any problems: no lubricant can be rinsed out and nothing can rust. Maximum safety due to many test trials Before they are used, all components are extensively tested. 135 trillion test cycles and 15,000 tests take place annually in the 4,000 square metre igus test laboratory in Cologne. 250 square metres of this is for the bicycle test rigs alone, on which all components such as wheels, handlebars and cranks are tested. This also applies to the new Reco frame. Hollmann: “We will use computer tomography (high-tech imaging) to check the first injection-moulded bicycle frames for potential problems such as air pockets in the composite material and carry out all relevant frame tests in our test laboratory.” Customers receive a 30-year guarantee from Advanced. For maximum safety, igus therefore relies on a large number of test procedures. “These are based on standardised tests, for example from the EFBE and TÜV,” emphasises Hollmann. “We also carry out our own test procedures − for example in our climate chamber.” With the data obtained, precise statements can be made about the service life of igus materials under different environmental conditions. Everything from a single source: from design to the finished product “With our bicycle components made of high-performance plastic, we are offering the bicycle industry access to a completely new technology,” says Hollmann. “In this way, we also appeal to OEM manufacturers who want to bring their own ideas into reality with us.” By using plastic, developers can completely rethink design and geometry. And with igus, you also get everything from a single source: fromdesign to research and development, mouldmaking, compounding, testing and production, right through to recycling. The just-in-time production line means that igus is able to deliver quickly and customers' storage capacities can be reduced. This makes the business more predictable and profitable as everything is produced to order. About igus: igus GmbH develops and produces motion plastics. These lubrication- free, high-performance polymers improve technology and reduce costs wherever things move. In energy supplies, highly flexible cables, plain and linear bearings as well as lead screw technology made of tribo- polymers, igus is the worldwide market leader. The family-run company based in Cologne, Germany, is represented in 31 countries and employs around 5,000 people across the globe. In 2023, igus generated a turnover of €1,136 billion. Research in the industry's largest test laboratories constantly yields innovations and more security for users. 243,000 articles are available from stock and the service life can be calculated online. In recent years, the company has expanded by creating internal startups, e.g. for ball bearings, robot drives, 3D printing, the RBTX platform for Lean Robotics and intelligent "smart plastics" for Industry 4.0. Among the most important environmental investments are the "chainge" programme – recycling of used e-chains − and the participation in an enterprise that produces oil from plastic waste. igus www.igus.eu The new bike frame is 3.3 kg, recyclable and moulded in a single piece (all pictures source: igus)