Novel High Performance Repairable and Recyclable Carbon Composite Ebike Frame for UK Manufacture

新型复合材料电动自行车提供了一个可持续的和轻量级的电动自行车框架开发使用热塑性材料。总部位于布里斯托的自行车制造商Starling Cycles、总部位于德比的编织专家Composite Braiding Limited和总部位于布里斯托的高价值制造弹射器中心National Composites Centre（专门从事复合材料和加工研发）联手开发了一种创新和可持续的解决方案，以解决现有的钢和复合材料自行车车架问题。现有的复合材料自行车不容易修理或回收，制造工艺不适合英国这样的高工资经济。拟议的工艺，编织和定制纤维放置，应确保通过自动化和可靠的制造工艺的高性能。这些工艺还以其高生产率、可靠性和低浪费而闻名，从而使当地生产成为可能。此外，电动自行车的续航里程在一定程度上取决于电动机在行驶过程中需要提供动力的重量。因此，轻量化的结构有助于增加自行车在需要充电之前的最大行驶距离。该项目将产生成本模型，生命周期评估报告以及完全组装和测试的电动自行车演示器，这是迈向商业化的第一步。对英国经济的积极影响将包括自行车制造业的重新支撑，以及在供应链中创造多达100个就业岗位。此外，这些技术还可以用于运动和休闲的许多其他领域，也可以用于交通或建筑。希望这种新颖的电动自行车将有助于为英国更可持续的未来做出贡献，通过更方便的私人交通工具增加骑自行车的人数，从而减少交通，从而减少空气污染。这将提高英国公众的生活质量、健康和福祉。

The novel composite Ebike offers a sustainable and lightweight Ebike frame development using thermoplastic materials. Starling Cycles, a Bristol based bike manufacturer, Composite Braiding Limited, a Derby based braiding specialist and the National Composites Centre, a Bristol based High Value Manufacturing Catapult Centre specialising in composite materials and processing R&D, joined forces to develop an innovative and sustainable answer to existing steel and composite bicycle frames. Existing composite bikes are not easily repairable or recyclable, and manufacturing processes are unsuitable for a high-wage economy, like which exists in the UK. The proposed processes, braiding and tailored fibre placement, shall ensure high performance through automated and reliable manufacturing processes. Those processes are also well-known for their high production rate, reliability and low waste, thus enabling local production. In addition, the range of an Ebike is, in part, determined by the weight the motors need to power during travel. Thus, lightweighting the structure helps to increase the maximum distance the bike can travel before recharging is required.The project will produce a cost model, life cycle assessment report and fully assembled and tested e-bike demonstrator in their first step towards commercialisation. The positive impact on the UK economy shall include the re-shoring of bike manufacture and creation of up to 100 jobs within the supply chain. Also, the technologies could be used in many other areas of sports and leisure, but also transportation or construction.It is hoped that this novel ebike will help contribute toward a more sustainable future for the UK, with increased uptake in cycling through a more accessible means of private transport - leading to a reduction in traffic and thus air pollution. This will improve the UK public's quality of life, fitness and wellbeing.