Mountain Bike Frame Innovation Using Thermplastic Composites - A Case Study

For over 20 years the bike industry has been using composite materials to make mountain bike frames and other components, becoming the default high end material in the past 5-10 years. Thermoset based carbon fiber composites have traditionally led the way, but recently the next generation technology of thermoplastic infused carbon fiber composites have entered the market as recyclability, impact toughness, and vibration damping become more important. In particular, a new class of mountain bike frames has hit the trails as produced by Revved Industries for their in-house brand, Guerrilla Gravity. Increased impact toughness and vibration damping of thermoplastic composites offer attractive performance advantages that are ideal for applications such as mountain bike frames and components. Several thermoplastic composite material options were investigated and PA6/carbon fiber produced by Toray Advanced Composites was selected. A significant breakthrough in thermoplastic composite part forming, co-molding, and fusing has led to a durable and robust design that sets thermoplastic frames apart from their thermoset counterparts. This paper will review the material selection, design and analysis, fabrication, and testing of a mountain bike frame that has proven itself in the market today.