Injection-moulded carbon composite e-bike frames from Germany – 100 % recyclable, one frame every 90 seconds.
ISOCO Bikes GmbH
Saalfeld (Schmiedefeld district), Germany · Estado de México, Mexico (sales partner PLAR)New on Amplifa
About ISOCO Bikes
ISOCO Bikes GmbH manufactures high-performance carbon composite e-bike frames at its Saalfeld (Schmiedefeld district) site using the injection moulding process. The frame is produced in one-shot moulding as a seamless component with hollow-volume geometries; every 90 seconds a frame leaves the injection moulding machine. The recyclable carbon composite materials used, sourced from the aviation industry, enable a lightweight, stiff design that generates over 50 % less CO2 emissions during manufacturing than conventional aluminium frames. The circular concept provides for end-of-life frames to be reused directly as raw material for the next frame generation. With an installed capacity of up to 3 million frames per year, the company is bringing bicycle frame production back to Europe. In addition to frame manufacturing, ISOCO offers complete e-bike fleets for corporate customers through ZE Fleet; in Mexico the company is represented by its sales partner PLAR Entertainment & Services.
- Site
- Saalfeld
- Processes
- Injection moulding of carbon composite bicycle frames (one-shot moulding,, Recycling of carbon bicycle frames (reuse of frame material for the next, Manufacture of injection-moulded carbon composite e-bike frames (one-shot process, 1 frame every, 100 % recyclable carbon frames, circular/recycling concept, ZE Fleet: corporate fleets of e-bikes
- Materials
- Carbon composite, Aluminium (reference material of conventional frames, not manufactured in-house), Carbon composite (aviation-grade materials), Injection moulding / one-shot moulding, Carbon frame recycling
- Industries
- Bicycle/e-bike industry, Fleet mobility
- 01
Development/engineering of the frame concept
- 02
Injection moulding (one-shot moulding) of the carbon composite frame
- 03
Recycling of the frame material for the next frame generation
- 04
Assembly/distribution (e-bikes, ZE Fleet)
Materials & Processes
Carbon composite (aviation-grade materials)
Recyclable carbon composite for injection-moulded, seamless e-bike frames with high stiffness at reduced weight and over 50 % lower CO2 emissions during manufacturing.
Injection moulding / one-shot moulding
Injection process for the seamless production of hollow-volume frame geometries with a cycle time of 90 seconds per frame.
Carbon frame recycling
End-of-life frames are fed directly back into the design of the next frame generation as raw material.
Locations
Saalfeld (Schmiedefeld district)
DEProduction plant / headquarters
- Lot size
- Large-scale production (up to 3 million frames/year)
- Materials
- Carbon composite
- Injection moulding machine for carbon composite (1 frame every 90 seconds)
Estado de México
MXSales partner (PLAR Entertainment & Services)
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Injection moulding of carbon composite bicycle frames (one-shot moulding,Plastics | – | – | – | 3,000,000 bicycle frames per year | Carbon composite (recyclable, aviation-grade materials) |
| Recycling of carbon bicycle frames (reuse of frame material for the nextPlastics | – | – | – | – | Carbon composite |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection moulding machine for carbon composite (frame production every 90 seconds) | – | – | – | – | Saalfeld, Germany |
Additional services