Moulded thermoplastic composites; lightweight and recyclable. The BCPR project.

Nacar Design designed a Ebike with a recyclable thermoplastic composite frame. This R&D project, which is called BCPR (bicicleta con cuadro de plástico reciclable - bicycle with recyclable plastic frame), includes technology, market and user-research, design, prototyping and validation. Various e-bike architectures were explored during the project. For the South European market, we designed a lightweight, cost-effective, and highly functional e-bike. Its frame is constructed from a small number of injection-molded shells, welded together, with integrated mechanical and electrical cabling. The e-bike frame can be manufactured using carbon fiber-filled polyamide compounds, resulting in an 18-19kg e-bike. Recycled carbon fiber can be sourced from discarded aerogenerator wings, and recycled polyamide from discarded clothing and fishing nets. Downstream, discarded BCPR frames can be shredded and repurposed for less critical structural components, such as car interior parts and accessories for the BCPR. Research is ongoing regarding the use of glass fiber-filled polyamide compound, as it offers a more cost-effective solution with a lower environmental impact.