Novel High Performance Repairable and Recyclable Carbon Composite Ebike Frame for UK Manufacture

The novel composite Ebike offers a sustainable and lightweight Ebike frame development using thermoplastic materials. Starling Cycles, a Bristol based bike manufacturer, Composite Braiding Limited, a Derby based braiding specialist and the National Composites Centre, a Bristol based High Value Manufacturing Catapult Centre specialising in composite materials and processing R&D, joined forces to develop an innovative and sustainable answer to existing steel and composite bicycle frames. Existing composite bikes are not easily repairable or recyclable, and manufacturing processes are unsuitable for a high-wage economy, like which exists in the UK. The proposed processes, braiding and tailored fibre placement, shall ensure high performance through automated and reliable manufacturing processes. Those processes are also well-known for their high production rate, reliability and low waste, thus enabling local production. In addition, the range of an Ebike is, in part, determined by the weight the motors need to power during travel. Thus, lightweighting the structure helps to increase the maximum distance the bike can travel before recharging is required.

The project will produce a cost model, life cycle assessment report and fully assembled and tested e-bike demonstrator in their first step towards commercialisation. The positive impact on the UK economy shall include the re-shoring of bike manufacture and creation of up to 100 jobs within the supply chain. Also, the technologies could be used in many other areas of sports and leisure, but also transportation or construction.

It is hoped that this novel ebike will help contribute toward a more sustainable future for the UK, with increased uptake in cycling through a more accessible means of private transport - leading to a reduction in traffic and thus air pollution. This will improve the UK public's quality of life, fitness and wellbeing.