Preliminary Assessment of Sustainable Material Replacement of Bicycle Frame Components Through Natural Composite-Based Reinforcement of FDM-Printed Green Co-Polyester Journalartikel uri icon

 

Abstract

  • Extending the service life of structural components through sustainable replacement is a key strategy for reducing material consumption and environmental impact in the cycling industry. This study evaluates the potential substitution of bicycle frame components, combining fused deposition modeling (FDM) with externally applied fiber tape reinforcement. Preliminary experimental validation was conducted on coupon specimens to assess the mechanical and environmental viability of the proposed material system. Two thermoplastic substrates, a bio-based green co-polyester (GreenTEC PRO, GT) and polycarbonate (PC), were printed at three orientations and reinforced with unidirectional carbon fiber (CF) or flax fiber (Flax) tapes. The results show that fiber position was the dominant factor governing both ultimate flexural strength (UFS) and elastic modulus (EF), accounting for over 74% and 81% of total variability, respectively. Carbon fiber reinforcement increased mean UFS from 60.6 MPa to 142.9 MPa, with peak values of 236.4 MPa, while flax fiber provided a statistically significant intermediate reinforcement, reaching up to 108.9 MPa. The bio-based GT substrate performed comparably to PC across all configurations, demonstrating that sustainability goals need not compromise structural performance. Bilateral fiber placement and 90° printing orientation consistently yielded the best mechanical response. These findings support the hybrid FDM/prepreg approach as a viable, tooling-free, and environmentally conscious strategy for the replacement of bicycle frame components.

Veröffentlichungszeitpunkt

  • 2026

Heftnummer

  • 10

Band

  • 16

Startseite

  • 4988