Emery bikes

History of Emery Bikes

AREVO, a company based in Silicon Valley that specializes in composite 3D printing, became the talk of the town when it printed what was referred to as the premier 3D printed commuter bike in the world. The use case, done in collaboration with Studio West, showed the capacity of AREVO to move from design to production. The 3D printed composite bike was manufactured in less than eighteen days, greatly reducing the amount of time it takes to create a new bike frame.

When AREVO was started in 2014, the company started by starting a wide variety of carbon nanotubes and carbon fiber materials for the goal of composite support. The carbon nanotubes launched by AREVO were said to be tougher than steel and could be used as reinforcement to the 3D array of plastics by AREVO. This is often said to have influenced the company’s entry into bike making. Later, Khosla Ventures, a venture capital company provided AREVO with seven million dollars enabling the expansion of the company. Following AREVO’s expansion, the company started developing lightweight and strong composite parts to be used for production purposes. AREVO raised an additional $12.5 million from Asahi Glass, and this funding was crucial in the initial plans of the company to print 3D bikes. Using its exclusive multi-axis RAM program and registered generative design techniques, AREVO began printing 3D bicycle frames for Franco Bicycles of California. The bikes produced under this partnership were marketed using the brand “Emery Bikes.” The bike’s universal-body carbon fiber frames were built using AREVO’s 3D printing technology known as DED and were later blended into the range of Emery bikes.

This particular application by AREVO caught on and the company’s AM composites platform is currently being used to manufacture a set of e-bikes for Franco Bicycles. This collaboration saw AREVO manufacture the world’s first continuous carbon fiber single-piece 3D printed unibody frame for Emory eBikes for Franco Bicycles.

Emery believes that life is sparked by movement, that’s why it delivers transformational and innovative e-mobility products that make your daily life more convenient. Emery’s first product was an electric adventure bicycle known as Emery One that’s ready to tackle any terrain or road. To mark the beginning of the partnership, Franco Bicycles and AREVO presented the Emery 1 eBike at the Sea Otter Classic cycling event held in Monterey, California. AREVO DNA, the composite 3D printing platform of AREVO, is unlike any other in the AM industry. One of its unique features is the free-motion robotics system with authentic 3D construction. AREVO DNA also uses a patented software that allows a direct void-free energy deposition technique designed to make optimal use of anisotropic composite materials, and also allows generative design techniques.

How Emery Bikes are Constructed

The unibody bike frame of Emery One is made using this unique technology. By printing the bike frame as one unit, instead of the traditional method of gluing different composite materials together, the Emery eBike is able to achieve superior stability and structural integrity. In addition to the superior performance, the 3D printed bike frames used on Emery bikes also significantly reduces the costs of production.

Similar to the premier 3D printed bicycle by AREVO, Emery One’s development was significantly faster than traditional manufacturing and development lead times for bikes. In this case, the technology reduced the time between design and final production from 18 months to a few days.

The technology’s flexible and iterative design represents a change in composites manufacturing and Emery bikes are leading this revolution. The continuous carbon fiber technology used in Emery bikes has been instrumental in boosting the performance and ride quality of the eBikes. Not only do the Emery bikes have a composite frame, but they also come with Bosch’s eBike drivetrain which offers an electric pedal-assist of up to 28 miles per hour.

In addition to the advantages of the cycling industry, AREVO’s AM technology will also positively impact other industries due to its unique capabilities. The capabilities include a higher degree of freedom for custom products, localized manufacturing, a fully automated production model, and an authentic serial volume manufacturing of composite parts.

The Emery One was launched in limited quantities. Pricing for the innovative 3D model started at $5,500. The 3d printed Emery bike featured an aerospace-quality carbon-fiber frame attached to a fully integrated battery of 500 Watt-hours and a 63 Nm Bosch motor. The manufacturing process of Emery One involved the optimization of each level of continuous carbon fiber in both performance and orientation for safety and performance requirements. The technology used in Emery One made producing fully customized eBikes possible on an on-demand basis leading to a greater degree of freedom in manufacturing.

The Emery bikes have set a new standard for high-performance bikes and are a major breakthrough for bike manufacturers. One of the breakthroughs achieved by Emery bikes is authentic serial, volume production of additive-manufacturing-made composite materials made using thermoplastics, which are durable, recyclable, and tougher, as compared to non-recyclable and brittle thermoset materials. Another breakthrough is that a fully-automated production model replaced the traditional labor-intensive manual process. Another breakthrough is great independence achieved through on-shoring or localized manufacturing. In addition, is the already mentioned design freedom to produce custom bikes on an on-demand basis, a phenomenon that AREVO refers to as DESIGN-PRINT-GO.

Post written by Jackson Steeves. Jackson is a jack of all trades, with previously published works on topics as varied as motorcycles to Nationwide Care Matters II policies. If it needs to be written, Jackson is the guy!

Where Emery Stands Now

Emery bikes

The technology used in Emery bikes provides a new design paradigm and has completely transformed design and production. The technology enables producers to push design boundaries that did not seem possible before. The use of a single continuous carbon fiber 3D printed frame eliminates the need for welding or gluing to hold the individual parts together. This is important because the use of a single bike frame makes the Emery bikes extremely impact resistant. The thermoplastics also allow the Emery bikes to be lighter and faster. For many cyclists having a bike that is extremely tough and light at the same time is a dream come true. It is not often that you find both these qualities present in a bike. For example, before the launch of Emery bikes, race bikes used in the Olympics were light, but would crack or crash when pushed too hard. On the other hand, bikes that were built to be tough were not light.

Although other companies such as Urwahn Bikes of Germany have successfully printed 3D bike frames, most of the time these bikes have been manufactured in sections, prior to being welded or soldered together. The Emery bikes are produced as a single part, which makes their frames extremely strong and impact resistant. The Emery bike was created to offer the most useful of both worlds: lightness and strength.

As mentioned earlier, the technology used in the Emery bikes enables a significant degree of customization. Every frame can be individually designed based on eighteen accurate measurements, allowing a custom fit for bikers between 4’7” and 7’4”. What’s more, if you take into consideration the extra adjustable settings like stiffness level and ride position, the bike has more than half a million possible combinations. The Emery bikes can be customized to accommodate various styles of riding such as racing, touring, street, or gravel. It can also be customized to accommodate different colorways and wheel materials.

However, AREVO is not the first company to apply AM in the production of bicycles. Many other firms have also applied 3D printed technology in their bike frames. Renishaw, for example, collaborated with Hope Technology and Lotus, to produce a track bicycle for the UK’s Cycling Team. Using the RenAM 500 System by Renishaw, designers created a prototype and made final parts to boost the bicycle’s track ability. Similarly, in 2019, MX3D, a Robotic Additive Manufacturing technology developer produced an updated version of its 3D printed bike known as Arc Bike 2.

Since their launch, Emery bikes have become a hit with cycling enthusiasts and novices alike. Different people love Emery bikes for various reasons. Cycling enthusiasts, for example, love Emery bikes because of the design, performance, and durability. Emery bikes generally perform better than ordinary bikes, and bike enthusiasts prefer them for racing. But bike enthusiasts understand that a good bike is not all about speed — a good bike has to be durable. Since bikes sometimes have an impact on other objects, it is important to have a bike that is extremely impact resistant and does not get completely destroyed after a single impact. The single bike frame used in Emery bikes ensures that you never have to lose a night’s sleep worried about your bike. People also love the fact that emery bikes can be customized on-demand. Customization ensures that you get a bike that’s perfectly tailored to your needs and comfort. The Emery bike has also set the bar in terms of what a “high-performance bike” means and has inspired many other companies to follow suit and produce similar bikes. Whatever the future holds for Emery bikes, one thing is for certain: they have established a mark in the cycling world with indelible ink and will always be remembered as one of the leaders of 3D printed bikes.