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by A. Fäh

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Quick Tech News


by Alexander Fäh

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Revolutionary Lion Bikes: Sustainable Children's Bicycles made with 3D Printer

  • KraussMaffei and partners revolutionize the bicycle industry with Lion Bikes, emphasizing sustainable production and innovative safety features.

  • The use of recycled carbon fibers and state-of-the-art injection molding technology, including 3D printing, allows for a significant reduction in CO2 emissions compared to traditional bicycle frames.

  • Lion Bikes are distinguished by their eye-catching design and integrated lighting system, enhancing the safety of young riders. They are set to hit the market in spring 2024, making a significant statement for sustainability in the bicycle industry.


Innovative Technology, Safety, and Sustainability: The Lion Bikes by KraussMaffei and Partner made with a 3D printer.

Cutting-edge 3D printer in action, creating intricate designs with precision.
The Lion Bikes - Children's bicycles with revolutionary 3D printing technology for enhanced safety and sustainability.

In a groundbreaking collaboration, KraussMaffei and its partners have developed a high-performance children's bicycle that prioritizes a stylish design, innovative safety features, and sustainable production. The Lion Bikes, initiated by former professional cyclists Marcel Kittel and Tony Martin, feature a frame and fork made from a high-performance polymer with recycled carbon fibers, manufactured by specialist Weber Fibertech.

The key breakthrough in producing these bicycles lies in the use of polyamide 6 (PA6) in combination with 40% recycled carbon fibers. Thanks to these robust and 100% recyclable materials, the main components can be produced using state-of-the-art injection molding.

Weber relies on the KraussMaffei MX 1600 injection molding machine in conjunction with the Water Injection Molding (WIT) process, a technology from PME fluidtec. WIT has proven to be ideal for manufacturing functionally complex, highly integrated plastic components with hollow body construction.

For the first time, the mass back-pressure method was applied in the WIT process for bicycle frames. The melt displaced by water is pushed back into the plasticizing unit and reused in the next shot for the frame or fork. This means there is no waste during production, reducing both material usage and the carbon footprint.

According to KraussMaffei, when comparing the production of Lion Bikes to conventional aluminum frames and forks, CO2 emissions are 67% lower for each bike produced. Additionally, component production in Germany shortens the supply chain and transport routes.

Friedbert Schmitt, CEO of Weber Fibertech, expressed enthusiasm for the technical performance of the MX series: "Processing high-performance polymers and recycled carbon fibers, along with production in Germany, sends an important signal towards sustainability in the bicycle industry."

In terms of safety, the Lion Bikes stand out. They feature a special paint that makes the frame glow and an unusually large lighting system with daytime running lights seamlessly integrated into the frame.

The first finished Lion Bikes are expected to be available on the market beginning in spring 2024.


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