Superstrata Bike and e-Bike

The thermoset carbon fiber composite and molded manufacturing processes used in traditional carbon fiber bikes are costly and present issues pertaining to complex stress calculations. This reduces the durability of bikes relative to strength and performance . Furthermore, the traditional injection molds can only produce a few standard sizes, limiting bicycle companies from accommodating a more diverse base of customers.

Superstrata embodies a revolutionary approach: thermoplastic carbon fiber composite crafted with proprietary 3D printing technology. Each carbon fiber has its directionality engineered by algorithms to optimize riding positions and accommodate multiple load scenarios. The unibody design also eliminates weaknesses in joints, increasing its strength-to-weight ratio. As a fully customizable bike, Superstrata sets a new standard: mass customization of all-carbon fiber bikes at significantly lower costs and shorter lead time.

The bike stands out thanks to its individually crafted frame, which allows for the most comfortable rides irrespective of distance and travel time. The innovation is that a bike is printed in a single piece using less labor – a feat previously impossible for a complex item that must be designed to support riders geometrically. Superstrata, therefore, represents not only a technological breakthrough, but a significant impact on futuristic urban commuting and cycling with its carbon fiber look and its exceptional performance.

Every part of the frame has its own geometry and load scenarios, and composite parts will have their own optimum positioning of carbon fibers to meet these requirements. Our 3D printing process looks like this: Arevo’s in-house software engineers the directionality of each carbon fiber. A robot arm then uses a laser to melt and bond the carbon fibers together accordingly, precisely placing them into their desired position and direction. With this process, Superstrata can achieve an unprecedented level of precision and aesthetic unibody design that was previously impossible using traditional materials or carbon fiber but with molding manufacturing methods.