Sustainability meets innovation: Igus showcases an e-bike made from recycled fishing nets at Eurobike

The Cologne-based company Igus is showcasing an electric version of its plastic bicycle at the Eurobike trade fair. The previous model covered 6,000 kilometres on a world tour through 25 countries and proved its worth in a variety of climates. This practical experience was incorporated into the development of the e-bike version.

Jens Boldt, Head of the Igus Bike division, explains: “We are confident that we are bringing an e-bike to market that is not only exceptionally durable, but has also been designed with circularity in mind from the outset.” All components are tested in the company’s own test laboratory before use.

Frames made from marine plastic

A Belgian partner collects lost fishing nets from boats near the coast, cleans them and processes them into plastic powder. According to the environmental organisation WWF, a third of the world’s plastic waste in the oceans consists of fishing gear such as nets and ropes.

The materials scientists at Igus have developed a process in which 50 per cent of the plastic used in the bicycle frame is made from this recycled material. The frame is manufactured using a special process that enables the production of seamless and robust hollow structures. This refined method results in a stiffer frame.

At the same time, the wall thicknesses have been reduced, allowing for a sleeker frame design. The new construction, featuring seat stays and chain stays on both sides, gives the orange and black bike a striking look. Igus manufactures the seat posts and handlebars using injection moulding. We had already had the chance to see how an Igus Bike is made during a factory tour.

Engine and range

Designed for urban cycling, this e-bike is powered by a 60 Nm rear-wheel motor. Power is transmitted via a timing belt made of carbon fibre and plastic. The battery provides a range of up to 120 km. The single-speed e-bike weighs 20 kg.

Metal is only used where it is technically necessary: in the suspension fork, the brake discs and the brake cables. From the bike frame to the wheels and the seat post, right through to the handlebars, 50 per cent of the e-bike is made of plastic.

Lubrication-free plain bearings

Bicycles that are often left out in the rain in urban areas frequently develop rust on the chain, seat post, spokes and welded joints on the frame. Owners have to go to great lengths to clean these parts, maintain them regularly or replace them entirely. The Igus Bike can be left out in the rain for years without corroding.

There is also no maintenance required at the bearing points. Igus uses lubrication-free plain bearings made from high-performance plastic on brake levers, pedals and dampers. Integrated, microscopically small solid lubricants are designed to enable long-term, low-friction dry running without lubricating oil.

Technical Specifications

• Price: 2,500 euros
• Motor: 60 Nm rear-wheel motor
• Range: up to 120 km
• Weight: 20 kg

Classification

​The Igus Bike, fitted with an e-bike motor, stands out in the current bicycle market as an environmentally conscious, technological innovation. At the same time, the Igus Bike is positioning itself in the urban e-bike segment, where low-maintenance and weather-resistant bikes are in demand. The design is particularly appealing to fleet operators and bike-sharing providers.

Unlike traditional e-bikes, which are often made of aluminium or steel, Igus uses a frame made from recycled plastic. This gives it a clear sustainability advantage, as it reduces the need for virgin material and gives plastic a new lease of life.