Sustainable Plastics Can Redefine the Future of E-bikes

E-bike production today is dominated by aluminum and steel. These materials, and often the bikes themselves, are primarily sourced from Asia. To gain a competitive edge, however, “OEMs are exploring new materials to reduce cost, enhance manufacturing efficiency, improve design and functionality, and offer more sustainable solutions,” said Megan Powers, global marketing manager for life solutions at advanced polymers supplier Syensqo (formerly part of Solvay).

In addition, according to Powers, there is a shift toward “regional manufacturing, predominantly in Europe. Supply-chain disruptions worsened by the pandemic, including semiconductor shortages and shipping delays, have all impacted the e-bike sector. Shifting to regional manufacturing for frames and other e-bike components can improve logistics, ensuring faster delivery by reducing dependency on external geopolitical factors, and also enhancing the after-sales market through local repairs,” said Powers.

Environmental selling points

Local, plastics-centric production also benefits the environment, which can be a selling point for e-bike buyers. In fact, Syensqo has conducted an internal lifecycle assessment, which shows that using specialty polymer injection molding for the e-bike frame component specifically reduces global warming potential by about 70% compared with traditional aluminum manufacturing. “Eco-conscious consumers are driving demand for sustainable urban transportation,” noted Powers, adding that plastics also can deliver personalization and design improvements.

Related:Igus Rolls Out All-Plastic Urban Bike

Syensqo views its Echo portfolio of sustainable grades with bio-based and/or recycled content as a natural fit for the e-bike market segment. One such series is the Ixef Para polyarylamide materials filled with either glass or carbon fiber, sometimes in combination, and in short- or long-fiber configurations. “To be fully efficient, these complex resin and filler blends must be combined with a specific part design and advanced processing technology like fluid-assisted injection molding,” emphasized Philippe Martin, senior technical development EMEA - expert melt processing, at Syensqo. Ixef Para materials deliver an ultra-smooth surface finish in structural thermoplastics with a metal-like feel and best-in class-appearance. The material’s extremely low water absorption ensures dimensional stability, and the Ixef Para Echo grades can reduce a product’s carbon footprint by as much as 74%.

The all-plastic e-bike

Plastic composites offer various benefits in bicycle applications, such as colorability and corrosion resistance. Image courtesy of Stajvelo.

Syensqo has partnered with Monaco-based Stajvelo to create a cutting-edge electric bike made entirely of plastic, showcasing a new high-performance Xencor Para LGF polymer. Among the benefits of this material are a unique combination of stiffness and impact resistance, insensitivity to corrosion stress cracking, no fissure propagation, outstanding creep and fatigue performance, and outstanding gloss and surface appearance, according to Syensqo.

“Injection molding [of colored compounds for the e-bike] cuts down on post-production operations like painting and polishing, which are essential tasks when making metal frames to prevent corrosion and to achieve a polished look,” noted Syensqo’s Powers. “Additionally, the ease of adding new functionalities allows OEMs to quickly innovate and adapt to new design trends and requirements in the fast-paced e-bike market,” she added.