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    World’s First 3D-Printed Carbon Fibre Unibody Bike Frame for New Line of eBikes from Franco Bicycles

    World’s First 3D-Printed Carbon Fibre Unibody Bike Frame for New Line of eBikes from Franco Bicycles

    Arevo, on April 10th, announced a partnership with boutique bike manufacturer Franco Bicycles to deliver the world’s first 3D printed, continuous carbon fiber single-piece unibody frame for a new line of e-Bikes Franco will sell under the “Emery” brand. The companies showcased the new “Emery One” eBike at the Sea Otter Classic bicycling event in Monterey, California, April 11 – 14, during exhibition hours.

    Arevo leveraged its unique DNA technology in the additive manufacturing which features patented software algorithms enabling generative design techniques for manufacturing of the ebike. The technology further facilitated free-motion robotics for ‘True 3D’ construction, and direct energy deposition for virtually void free construction all optimised for anisotropic composite material.

    With the construction of a Unibody bike frame, Arevo technology has laid down a new benchmark for high-performance bikes. Unlike the current composite frames made of many parts glued together, Arevo has successfully realized its creation as a single part. The company has achieved unprecedented structural integrity and stability by efficiently deploying AREVO’s intelligent continuous carbon fibre placement technology. Finally, the AREVO DNA AM process takes the design and final manufacture of a bike frame from 18 months to just a few days at a significant reduction in product development costs.

    AREVO’s new multi-purpose facility has started production of these frames and this achievement with the Emergy One represents several breakthroughs for bicycle manufacturers, with implications for other industries as well. These breakthroughs include:

    • True serial, volume production of AM-made composite parts that are made with thermoplastic materials, which are tougher, durable and recyclable, as compared to brittle and non-recyclable thermoset materials
    • A replacement of a laborious manual process with a fully-automated, ‘lights out’ production model.
    • Delivering on the promise of localised manufacturing or ‘on-shoring’, which creates greater independence for bike brands
    • A much greater ‘freedom of design’ for bike manufacturers that creates the possibility of fully-customised bikes made on an “on demand” basis, an approach AREVO calls ‘DESIGN. PRINT. GO.’

    Hector Rodriguez, Co-Founder of Emery Bikes commented, “We chose AREVO technology because its iterative and flexible design represents the new age in composites manufacturing, and we wanted to be the first bike company to help lead this revolution. AREVO’s continuous carbon fibre technology has been instrumental in achieving the ride quality and high-performance requirements we set out to accomplish with the Emery One.”


    “This is the first Composite Additive-Manufactured bike frame and it represents an important milestone for the AM industry as AREVO is delivering on the promise of on-demand manufacturing of composite parts in volume now,” said Hemant Bheda, AREVO Co-Founder and Chairman. “With the introduction of the Emery One, the transformation of the global composite bike industry has begun.”

    Bill Stephens, renowned industrial designer of Studio West collaborated with the AREVO and Franco teams to design the Emery One bike frame. Mr. Stephens said, “AREVO DNA offers a new paradigm for product designers, it forever changes how we can design and build anything. This technology allows us to push design boundaries in a way that was impossible until now. AREVO is changing the paradigm to ‘Manufacturing for Design’.”

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