​Actofive goeas e-bike: This CNC-machined enduro bike can also be ridden without a motor!

Conclusion by Max Fuchs, BIKE editor

Actofive isn’t doing things by halves with its first e-bike concept. Rather than retrofitting an existing frame with a motor and battery, the Dresden-based CNC manufacturer is developing a completely new platform. The key feature: The frame is designed to function both as an e-bike with a Maxon drive and as a non-motorised bike with a Pinion gearbox. It also features swappable batteries with capacities of 400 or 600 Wh, up to 170 mm of rear suspension travel and countless adjustment options.

What’s particularly exciting is that Actofive doesn’t want to build an e-bike that’s as heavy as possible with the longest possible range, but rather to retain the riding dynamics of a classic mountain bike. That’s why the battery isn’t fixed in the down tube; instead, it can be removed and swapped for a fresh one when needed. Technically, this is made possible by a frame that is entirely CNC-machined from 7075-T6 aluminium.

However, there is as yet no finished production bike available for sale. Actofive is initially presenting a validated engineering and layout concept and is expressly inviting the community to get involved in its further development.

Actofive E-Bike Concept – key facts

• Frame: fully CNC-machined from 7075-T6 aluminium
• Enduro suspension travel: 170 mm at the rear / 180 mm at the front
• Trail suspension travel: 150 mm at the rear / 170 mm at the front
• Drive system: Maxon AIR S motor or Pinion gearbox with Smart.Shift and belt drive
• Battery: removable, 400 or 600 Wh
• Wheel configurations: 29", Mullet, Super-Mullet with 32" at the front
• Suspension design: four-link with Horst-Link
• Down tube storage space: with the Pinion configuration, space for around two water bottles

One frame, two worlds

Actofive is rethinking the e-bike concept. The platform is not intended to be limited to a single drive system. Those who want electric assistance can choose a suitable Maxon drive from Switzerland. Those who prefer to cycle under their own steam can fit the same frame with a Pinion gearbox, complete with Smart.Shift and a belt drive.

At first glance, this sounds like a technical gimmick. In fact, there’s an interesting idea behind it: Actofive isn’t developing two bikes, but a single shared platform for two completely different drive systems. Both versions use the same frame interface.

CNC rather than carbon

Visually, the Actofive remains true to its established design. The entire frame is made from 7075-T6 aluminium, machined from solid blocks. The characteristic CNC finish is therefore also a feature of the e-bike.

Take out the battery, enjoy the ride

When it comes to the battery, Actofive takes a consistently user-friendly approach: rather than fitting it permanently into the frame, the battery can be easily removed. This allows the rider to choose between 400 and 600 Wh, or to do without the battery altogether. In the non-motorised Pinion configuration, the space freed up in the down tube becomes a handy storage compartment.

The replaceable battery also offers advantages on long journeys: if you need a longer range, simply take a second battery with you and swap it whilst on the move.

The battery is housed behind a cover on the underside of the down tube. There are different covers for the two battery sizes: the slim version accommodates the 400 Wh battery or the Pinion configuration, whilst the extended cover is used for the 600 Wh battery.

The hole in the down tube – and a rather tricky problem

However, a removable battery presents a design problem: cutting a large hole in the down tube weakens the frame. Torsional stiffness, in particular, suffers.

The conventional solution would be simple: use more material. Actofive takes a different approach. Using topology optimisation, the manufacturer distributes the wall thicknesses strategically along the load paths. Where high loads occur, more material is retained; in less critical areas, weight can be reduced.

Actofive is thus seeking to combine the rigidity of a closed down tube with the practicality of a removable battery and a reasonable weight.

Four abbreviations for a fairly flexible framework

If you’ve already switched off mentally at the mention of MPT°, NYT°, ART° and ATT°, you should hang on for a moment. There’s actually a rather interesting modular system behind these abbreviations.

MPT° – Modular Pivot Technology: The main pivot point can be replaced and adjusted. This allows Actofive to influence geometry, anti-squat and anti-rise.

NYT° – No-Yoke Technology: Actofive structurally integrates the yoke and pivot axis. A splined shaft connection transfers the forces directly to the chainstays whilst also creating space for the motor or gearbox.

ART° – Adjustable-Ride-Technology: Interchangeable dropouts and modular seat stays allow for different geometry and wheel configurations. Options include 29”, 29” with a longer chainstay, mullet, mullet with a long chainstay, and a super-mullet setup with a 32-inch front wheel.

ATT° – Adjustable-Travel-Technology: Two different shock mounts provide space for two different shock sizes. A 225 × 65 mm shock absorber provides 170 mm of rear suspension travel, whilst a 205 × 55 mm shock absorber reduces this to 150 mm.

This means that two different travel classes can be achieved using the same platform.

Storage space instead of a battery

The concept is particularly interesting in the Pinion version without a motor. Where the battery would normally be fitted on an e-bike, Actofive has created additional storage space. The volume is said to be roughly equivalent to two standard water bottles.

Tools, hoses, spare parts or food can be stowed away directly in the down tube. For long rides, this should provide considerably more space than conventional frame storage compartments.

Six months of CAD instead of six years of development

Behind the project is not just any new bike brand, but METZNER Engineering GmbH, the engineering firm behind Actofive. According to the manufacturer, the first phase of development took six months – from the initial CAD designs to the validated system layout.

FEM was one of the methods used. The engineers simulated loads and stress distributions and, based on these, optimised the ratio of stiffness, strength and weight.

Before the CNC milling machine was allowed to cut through the aluminium, physical mock-ups and 3D-printed prototypes were also produced. Actofive used these to check the installation space, the ergonomics and how easily the parts could be manufactured.

Not yet a production bike

And this is perhaps the most important point: with this new frame, Actofive is not yet presenting a finished production model.

According to the manufacturer, the technical foundations are in place and physical validation is currently underway. At the same time, Actofive is deliberately choosing to publicise the concept at an early stage. Feedback from riders will be incorporated into the ergonomics, operation and practical details.

This makes the new frame less of a finished product and more of a glimpse into the workshop. Actofive shows where the journey might be heading – and, in doing so, offers a surprisingly deep insight into its inner workings.

Editorial commentary

Actofive remains true to itself even when it comes to e-bikes. Rather than rushing a frame with a motor onto the market as quickly as possible, the CNC manufacturer is developing a technically fascinating platform. In particular, the combination of a removable battery, Maxon drive, Pinion option and adjustable kinematics sets this concept apart from the usual run-of-the-mill e-enduro bikes.

However, it remains to be seen whether the concept will ultimately make it onto the trail as it stands, and what further elements may be added following the concept presentation as a result of external input.