The first 100 igus bikes go on the road

The first optimized series of the plastic bicycle is ready. igus is setting up its own production facility in Cologne.

The time has finally come: after a long period of development work, the igus:bike, a bicycle made of 92 percent plastic with a high proportion of recycled material, has gone into series production. The Dutch development partner MTRL is currently producing the first 100 units together with igus. At the same time, the plastics specialist is building its own production line at its Cologne (D) location to increase production capacity to 10,000 units over the next two years. This brings the companies one step closer to their sustainability vision of transferring plastic waste into a circular economy and using it for the urban mobility of the future.

About 3.5 years ago, Frank Blase, CEO of igus, launched a sustainable project: using mountains of plastic from the world's landfills to produce plastic bicycles: durable and maintenance-free city bikes that are corrosion-free and dirt-repellent, can easily withstand years of outdoor wind and weather, thus revolutionizing the mobility sector, not only in cities, but also at campsites, hotels, trade fairs and business sites. A win-win situation for people and the environment. "We are delighted that we are now one big step closer to realizing this vision," says Mark van de Waal, Marketing Manager at igus B.V. "The igus:bike is finally hitting the road under a new name in its first small series." The new branding for the series product was recently announced at the Cyclingworld Europe trade fair (March 15-17, 2024) in Düsseldorf. Dutch development partner MTRL is currently producing 100 units together with igus. Once the vehicle is approved for road use, the company plans to deliver it quickly to the first of about 1,200 customers who pre-ordered the bike. "To reduce the waiting time for the remaining orders, we are currently building our own production line for the bicycle at our company location in Cologne. We plan to produce 10,000 bicycles with the expanded capabilities," said Van de Waal. The retail price of the plastic bicycle is around €1200.

The igus bicycle consists of 92 percent plastic

The go-ahead for series production should have been given a few months ago. However, some optimizations to the igus:bike were time-consuming and essential for durability. One of these involved further increasing the proportion of plastic. The few parts that were still metal in earlier prototypes, such as the seat post or brake lever, are also plastic in the current version. The engineers have also increased the steering angle so that riders can take corners better. Other new features include a freewheel in the drivetrain so the wheels even turn without pedaling, wear-resistant xiros ball bearings that make the wheels run even smoother and without lubrication, and a two-legged stand to safely park the bike. "The igus:bike, which weighs about 17 pounds, is now made of 92 percent plastic," says Mark van de Waal. "From the frame to the bearings to the drivetrain, which has long been considered virtually impossible in the industry."

Recycling rate already 50 percent - and rising

igus and MTRL are using rotational molding and injection molding to make bicycle parts from granules made from recycled plastic waste, including fishing nets. The engineers and materials experts have succeeded in reducing the proportion of virgin plastic to 50%. "We are now continuing to invest in research and development to increase the recycling rate to 75% as soon as possible and even to 100% in the long term," Van de Waal emphasizes. "With this high recycling rate, we are accelerating the circular economy for plastics. Plastic in landfills is therefore becoming an increasingly valuable resource."