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10th April 2019, Silicon Valley, CA

Unibody frame now in series production

A new line of eBikes will be sold under the Emery brand. © Arevo

A new line of eBikes will be sold under the Emery brand. © Arevo

Silicon Valley-based Arevo has announced a partnership with boutique bike manufacturer Franco Bicycles to deliver the world’s first 3D printed, continuous carbon fibre single-piece unibody frame for a new line of eBikes to be sold under the Emery brand. 

The two companies will showcase the new Emery One eBike at the Sea Otter Classic cycling event in Monterey, California, from April 11-14.

Arevo DNA additive manufacturing technology features patented software algorithms enabling generative design techniques, free-motion robotics for ‘True 3D- construction, and direct energy deposition for virtually void free construction – all optimized for anisotropic composite materials. 

The Arevo frame is made as a single part, in contrast to current composite frames, which are made of many parts glued together. With the company’s intelligent continuous carbon fibre placement, unprecedented structural integrity and stability are achieved.  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.

The Arevo frame is made as a single part, in contrast to current composite frames. © Arevo

The Arevo frame is made as a single part, in contrast to current composite frames. © Arevo

The frames are in production now at Arevo’s new multi-purpose facility in Milpitas, California, and the Emery One represents several breakthroughs for bicycle manufacturers, with implications for other industries as well. These include:

True serial, volume production of AM-made composite parts are made with thermoplastic materials, which are tougher, more 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 freedom of design for bike manufacturers.

“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,” said Hector Rodriguez, co-founder of Emery Bikes. “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.”

Renowned industrial designer Bill Stephens of StudioWest collaborated with the Arevo and Franco teams to design the Emery One bike frame.

“Arevo DNA offers a new paradigm for product designers – it forever changes how we can design and build anything,” says Stephens. “This technology allows us to push design boundaries in a way that was impossible until now.”

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