For four years, I was the Co-founder of BorderBike, an Italian sustainable bamboo bicycle company. I designed and manufactured bicycle frames and fabricated bicycles using bamboo as a construction material. The frames were assembled using synthetic fibre/epoxy resin composite joints with an inner 3D printed shape. The bikes were mostly custom made, and then brought to market.
BorderBike bikes was born from the idea of two engineers friends that wanted to prove a sustainable product like wood can compete with traditional high-end technologies. The concept of BorderBike frames came from a desire to prove that engineered natural materials can perform as well as industrial manufactured products. With a focus on producing composite joints with the best possible processes on an artisanal scale, the weight of BorderBike race frame reached an outstanding weight of 2.1 Kg.
To reach the goal, the following techniques were intensively involved:
VRTM (Vacuum Resin Transfer Molding) - This technique uses a vacuum pump to wet the fibers. This system helps to achieve a better fibre vs resin ratio and to reduce the excess of resin.
3D design and print - Using software modelers, the inner sides of the frame joints were printed with a foam-like materials. Having an inner shape ensures a stiffer and lighter joint, while keeping the frame aesthetically good looking.
Custom composite reinforcing - To ensure a perfect balance between weight and strength, each joint was manufactured combining different type of fiber fabric and fabric-weight. We started to manufacture the joints using hemp fabric, which then left its place for carbon fiber, and some limited usage of Kevlar.
During the activity, BorderBike received great attention from specialized media. See below the article published on the Italian bicycle magazine BiciTech in 2015.
