Lightweight e-bike supports ocean health

In response to a growing demand for low-maintenance e-mobility in cities, igus has developed a lightweight e-bike partly made from recycled plastic.

The bicycle is an enhanced electric version of the company’s plastic igus:bike, which was taken on 1.5-year world tour to test its hardiness. Both models consist of 50% recycled fishing nets, providing a sustainable option for the urban commuter. The e-bike retails for €2500.

“We are convinced that we are launching an e-bike that is not only particularly durable, but also fits in with the idea of circular economy. With the electric version of our igus:bike, we are responding to the increasing demand,” said Jens Boldt, Head of the igus:bike Business Unit.

Boldt and his team were inspired by the igus:bike’s world tour, which took in 25 countries. The plastic bike covered almost 6000 km and demonstrated its durability in various climate zones.

“The tour provided us with valuable insights,” Boldt said. “Many components have already shown their robustness under real conditions in everyday life. This experience went into the development of the e-bike.

“We are using this ongoing practical experience to continuously enhance both the igus:bike and the e-bike.”

All components are also put through their paces in igus’s in-house test laboratory before use, Boldt said.

The new e-bike is made of 50% plastic, from the bicycle frame to the wheels and the seat post to the handlebars. Metal is only used when technically necessary, eg, for the suspension fork, brake discs and brake cables. Designed for urban traffic, the single-speed e-bike weighs about 20 kg and works with a 60 Nm rear-wheel motor and a toothed belt made of carbon fibres and plastic. The battery allows a range of up to 120 km.

A bicycle that supports healthy oceans

According to World Wildlife Fund (WWF), around a third of the world’s plastic waste in the seas consists of fishing gear such as nets and ropes. To reduce this waste, igus works with a Belgian partner to source plastic for the igus:bike. The Belgian organisation collects nets that fishing boats have lost near the coast, cleans them and processes them into plastic powder. “Our materials scientists have managed to ensure that 50% of the plastic for bicycle frames can be made of this recycled material,” Boldt said. For production, igus relies on a special process that was already used in the previous bike model and can produce seamless and robust hollow bodies. “However, we have refined the process to such an extent that the frame now shows a higher stiffness,” Boldt said. “This allowed us to reduce the wall thicknesses and make the frame design much slimmer.” igus manufactures other components such as seat posts and handlebars via injection moulding.

Water-resistant for urban cyclists on the go

The igus e-bike is designed to be left out in the rain without suffering damage. On traditional bikes, metal components such as the chain, seat post, spokes and welds on the frame often rust, resulting in expensive cleaning, maintenance or replacement. “The igus:bike, in contrast, is almost maintenance-free,” Boldt said.

According to igus, the bicycle can stand in the rain for years without corroding. It’s also designed not to require any maintenance at the bearing points. This is thanks to lubrication-free plain bearings made of high-performance plastic, eg, on brake levers, pedals and dampers. Integrated, microscopic solid lubricants support low-friction, dry operation in the long term without lubricating oil.

Image caption: igus e-bike. Image: Supplied