In order for all electric bikes to make transportation easier and more enjoyable, there is one complaint that continues to haunt them: weight. However, slowly but surely, we are starting to see more electric bikes approach the weight of traditional bikes with smarter designs and lighter components.
An upcoming bike called Superstrata, launched today to preorder on Indiegogo in regular and electrified versions, aims to further expand the limits of lightweight electric bikes by using a 3D printed unibody carbon fiber manufacturing process.
Weighing in at around 24.2 pounds for the electric model, called the Superstrata Ion, the bike is not only lighter than virtually any other electric bike, but it also claims to be much more durable than existing carbon fiber, steel and aluminum models. And I say ‘around’ 24.2lb because the Superstrata has another trick up its sleeve: The 3D printing process means that each model is tailored to the individual rider’s size, allowing up to 500,000 variations of the unibody frame.
Plus, the Superstrata is doing it without a fancy price tag, with a $ 2,500 release on Indiegogo ($ 1,799 for the first 500 orders) and an MSRP of $ 3,999. The non-electric version comes with a pre-order price of $ 1,799 ($ 1,299 for the first 500 orders) and a retail price of $ 2,799.
The Superstrata is made by a Silicon Valley company called Arevo, which had previously created components for the aerospace and medical industries; its CEO, Sonny Vu, had previously helped found Misfit, the sportswear company. The idea of making a bike seems to have started first as a way to showcase Arevo’s 3D printing technology, before taking the effort more seriously. The company hired Bill Stephens, a veteran bike designer whose StudioWest consultancy has created products for people like Giant, Cannondale, and others, to help develop the product.
Most unibody carbon fiber frames require careful arrangement and a multitude of carbon fiber sheets around a mold, using thermosetting compounds that are then ‘cooked’ basically to cure. It is a laborious handmade process that inevitably leads to some variation from one model to another.
Arevo’s 3D printing process instead uses a thermoplastic compound that instantly cures during printing and is supposed to be “significantly stronger and much more impact resistant,” according to designer Bill Stephens in a 2019 Eurobike presentation. on prototype models. 3D printing, in theory, also gives Arevo more control over how its frames are resistant to the various dynamic forces that bikes are regularly subjected to and allows the company to quickly iterate on designs.
In fact, Arevo says it’s not really focusing on making the lightest carbon fiber frames anyway. The Superstrata Terra, the non-electric model, has a total weight of approximately 16.5 pounds, very light, but not unknown.
Instead, the company’s focus is on durability and reliability, with material the company says will never chip. It claims that its design is “61 times stronger than steel”, “51 times stronger than aluminum” and “15 times stronger than titanium”. In comparison, it claims that competitors’ high-end thermoset carbon fiber bikes are roughly ‘2 times weaker’ than aluminum, let alone ‘bargaining bin’ carbon fiber. Also, unlike traditional carbon frames, Arevo frames are recyclable.
The proof, however, is in the pudding. Superstrata’s strength claims make intuitive sense, but I’d like to see the company show us that its prototypes can deliver on their claims with some well-designed durability tests against the competition.
It’s also worth noting that while the frame and weight are impressive, the electronics aren’t particularly notable, with a 250W rear hub motor, a 20mph speed limit, and a 125Wh battery. Arevo claims it will get up to 60 miles from that little battery, which could be possible given the use of a torque sensor and lightweight frame, but would estimate the actual range to be less.
On the other hand, if you’re investing in such a light bike with these specs, then the slight specs probably don’t matter much to you. This is an electric bike for people who want something that rides like a normal bike and has assistance like cousin, unlike some models that are basically electric mopeds.
Aside from those reservations, the technology behind the design is impressive, and the possibility of thousands of variations through 3D printing is exciting. If the idea of a custom 3D printed carbon fiber bike has tickled you, you can pre-order in the Indiegogo campaign. The first units are expected to begin shipping in December. with subsequent batches to come out in early 2021.
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Posted on Jul 13, 2020 – 15:00 UTC
