The bicycle industry is a sector of the economy that includes companies involved in the design, manufacturing, distribution, and sale of bicycles and related products. This industry encompasses a wide range of products, from basic bicycles for everyday use to high-end racing bikes, electric bicycles, and accessories such as helmets, locks, and apparel. CNC machining for the bicycle industry is very common and critical for helping to more sales.

The global bicycle market has seen significant growth in recent years, driven by factors such as increasing interest in cycling as a form of exercise and transportation, the rise of e-bikes, and government initiatives promoting cycling infrastructure. According to a report by Grand View Research, the global bicycle market size was valued at USD 47.51 billion in 2020 and is expected to grow at a compound annual growth rate (CAGR) of 6.1% from 2021 to 2028.

In addition to traditional bicycles, the industry has seen significant growth in electric bikes (e-bikes) in recent years. E-bikes are equipped with an electric motor that assists the rider’s pedaling, making it easier to climb hills and travel longer distances. The global e-bike market size was valued at USD 15.42 billion in 2020 and is expected to grow at a CAGR of 7.9% from 2021 to 2028, according to a report by Grand View Research.

Why Use CNC Machining For Bicycle Industry

CNC (Computer Numerical Control) machining has become a popular manufacturing method in the bicycle industry due to its precision, speed, and flexibility. Here are some of the reasons why CNC machining is widely used in the bicycle industry:

Precision and Tight Tolerance

CNC machines are highly precise, producing accurate and consistent parts every time. This is crucial in the bicycle industry where even minor differences in parts can affect the performance of the final product. CNC machining allows manufacturers to produce parts with tight tolerances, ensuring the components fit together seamlessly.

Speed and Short Lead Time

CNC machines can produce parts quickly, allowing manufacturers to meet tight production schedules and reduce lead times. This is important in the highly competitive bicycle industry, where companies need to get their products to market as quickly as possible.

Flexibility Custom Fabrication

CNC machines can be programmed to produce a wide range of components, including complex shapes and geometries. This allows bicycle manufacturers to create custom parts and components that meet the unique needs of their customers.

Cost-effective

Although CNC machining may have a high initial cost, it can be cost-effective in the long run. CNC machines can produce parts with minimal waste, reducing material costs, and eliminating the need for multiple setups and manual labor.

Consistency

CNC machining ensures that each part is produced consistently, regardless of the batch size. This is important in the bicycle industry where manufacturers need to produce large quantities of identical parts.

Overall, CNC machining has revolutionized the bicycle industry by allowing manufacturers to produce high-quality, precise, and customizable components quickly and efficiently.

CNC Machining Materials For Bicycle Industry

The bicycle industry relies heavily on CNC machining to create precise parts that can withstand the wear and tear of regular use. Some of the most common materials used in CNC machining for the bicycle industry include:

Aluminum Alloy

Aluminum is a lightweight, strong, and durable material that is commonly used in the bicycle industry. It is easy to machine and can be anodized to add corrosion resistance and aesthetic appeal. Such as 5053, 6061, 6063, 7075 etc……

Carbon fiber

Carbon fiber is a composite material that is extremely lightweight and strong. It is often used in high-end bicycles and bicycle components, such as frames, handlebars, and wheels. However, it is more difficult to machine than other materials.

Titanium

Titanium is a strong and lightweight metal that is also corrosion-resistant. It is often used in high-performance bicycles and bicycle components, such as frames, forks, and handlebars.

Steel

Steel is a strong and durable material that is commonly used in bicycle frames, forks, and other components. It is easy to machine and can be coated with various finishes to improve its appearance and corrosion resistance.

Plastics

Various plastics, such as nylon, polycarbonate, and PVC, are also used in CNC machining for the bicycle industry. These materials can be lightweight and strong, and they offer good resistance to impact and wear.

The choice of material for CNC machining in the bicycle industry depends on the specific application and performance requirements of the part or component being manufactured.

Bicycle Frame Machining

Our latest project at Step Rapid involved the design and development of a fully machined frame.

This is machined from billet 7075 aluminium and bonded together using aerospace adhesives. While it’s not the most cost-effective process, there are numerous advantages…

Reduced supply chain

The number of manufacturing processes and overall supply chain is significantly reduced when compared to conventional welded frames that involve; tube forming, cutting, welding, alignment, heat treatment, etc.

Lower MOQ’s

The large MOQs typically required to order bicycle frames are drastically reduced. This means that the associated risks and upfront costs are also reduced- which is great for any startup company!

Sustainability

The simplification of the supply chain has the potential to significantly reduce the product’s carbon footprint. All waste material from machining is easily recycled.

Joining of 7075 aluminum

the bonding process allows for the joining of 7075 aluminum, which is an advanced alloy with great mechanical properties, but it cannot be welded within a conventional frame.

Accuracy and repeatability

the CNC machining process is super accurate and repeatable meaning that there are much fewer quality issues. Important features such as BB threads and pivot locations can also be accurately machined.

Setup costs

the accuracy of the CNC process allows for a self-aligning design, meaning that there is no the requirement for expensive tooling, jigs, or post-machining capabilities when setting up.

Flexibility

CNC machining is highly flexible, allowing companies to move from different suppliers and easily make design and development changes. Onshoring is also possible, with CNC machining capabilities readily available in Europe and the US.

Performance

The machining process allows for the wall thicknesses and internal features of the frame design to be tuned to specific weight and stiffness characteristics. Similar to that of a high-end carbon fibre frame.

Aesthetics

The frame has a unique aesthetic and will stand out from the crowd. The form and angles of the design are specific to the function and the CNC machining process.

How to Proceed Quality Control for CNC Machining Bicycle Frame

CNC machining is a widely used method in the manufacturing industry, including bicycle frame production. To ensure the quality of CNC machining for bicycle frames, here are some key steps that can be taken:

Define and establish quality standards

Clearly define the quality standards for the CNC machining process for bicycle frames, including dimensions, tolerances, surface finish, and other relevant specifications. These standards should be established in collaboration with the manufacturer and the customer.

Use high-quality materials

Use high-quality materials for the manufacturing of the bicycle frame. Ensure that the raw materials are free from defects and meet the required specifications.

Set up quality control points

Set up quality control points throughout the manufacturing process to ensure that quality standards are met at each stage. Inspections can be done manually or through automated systems, such as CMM (Coordinate Measuring Machine).

Conduct in-process inspections

Conduct regular in-process inspections to monitor the quality of the product during the manufacturing process. This will help identify any issues early on and prevent them from becoming major problems.

Final inspection

Conduct a final inspection to ensure that the finished product meets all the quality standards set for the bicycle frame. This inspection should be done by trained personnel who are familiar with the quality standards and specifications.

About Step Rapid

At Step Rapid, our focus is on providing you with the finest custom manufacturing services in rapid prototyping, rapid tooling and low-volume manufacturing. Our international service team has been well-trained and experienced hundreds of projects to global customers and got high satisfactions. Engineers and technicians are dedicated to making your custom parts with applying the most optimal solutions according to you requirements, using the most advanced equipment and techniques including multi-axis CNC machining , plastic injection molding and so on.  We’re here to turn your ideas into reality quickly by custom manufacturing, accurately and at a great price.

Step Rapid offers the most complete portfolio for all your on-demand manufacturing needs. From prototype to production and simple projects to complex, we can do it all for you.