Evari Bikes
Strengthening e‑bike frames using graphene
Accelerating product development with state-of-the-art facilities and expert knowledge
UK-based start-up, Evari Bikes Ltd, has worked with CPI to innovate the design and build of its high-end e‑bikes with the aim of accelerating the route towards commercialisation. Evari Bikes builds high-quality composite e‑bikes for the commuter market with a focus on strong, lightweight frames that minimise the wear and tear associated with the rapid speeds that e‑bikes are capable of.
Evari Bikes worked with CPI to strengthen their frames using graphene. CPI carried out the proof-of-concept to embed it into the carbon fibre resin of the frames, helping Evari Bikes to push this towards commercialisation. Furthermore, Evari Bikes has the desire to incorporate strain gauges into e‑bike frames as a proactive health and safety measure so that users can monitor their frame’s integrity. To this end, CPI has worked on a feasibility study of screen-printed strain gauges embedded in the bike frame.
![](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/EV_01-evari-bikes-image.png?w=1920&h=1080&q=60&fm=jpg&fit=crop&dm=1583231532&s=ef0ab6e33f6cad0a9754e41b8caf7ab7 1920w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/EV_01-evari-bikes-image.png?w=1120&h=630&q=60&fm=jpg&fit=crop&dm=1583231532&s=dbfe3f359a4ddad052e6a7f52c834f81 1120w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/EV_01-evari-bikes-image.png?w=2240&h=1260&q=45&fm=jpg&fit=crop&dm=1583231532&s=b2a0d8f070bddad2c53665bb4080f119 2240w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/EV_01-evari-bikes-image.png?w=800&h=450&q=60&fm=jpg&fit=crop&dm=1583231532&s=e156310d74842bc0f963bfde38510b7d 800w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/EV_01-evari-bikes-image.png?w=1600&h=900&q=45&fm=jpg&fit=crop&dm=1583231532&s=fa5f442b2eea33277fc69dd02ac0beaf 1600w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/EV_01-evari-bikes-image.png?w=480&h=270&q=60&fm=jpg&fit=crop&dm=1583231532&s=eae9b913fe4548da9c99a35630e3f378 480w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/EV_01-evari-bikes-image.png?w=960&h=540&q=45&fm=jpg&fit=crop&dm=1583231532&s=10847ec60d7ac1d32a17688736389d1f 960w)
“ CPI has provided us with technical facilities and expertise in graphene technology and printed electronics that are not readily available to start-ups. The work at the National Graphene Facility to develop a graphene-impregnated carbon fibre frame has greatly accelerated the route to market for our innovative e‑bike. ”
![Craig McDonald Craig McDonald](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/craig-mcdonald.jpg?w=100&h=100&q=60&fm=jpg&fit=crop&dm=1632738283&s=2076aa3fe7cf6e3c8e9aaaf112475541)
Partners
Achievements
Inputs
- Technical expertise
- Access to state-of-the-art facilities and equipment
- Securing funding via ERDF and LEP programmes
- Materials testing
Outputs
- Graphene formulation testing
- Small-scale impact testing on graphene-impregnated carbon fibre epoxy resin
- Feasibility study on screen-printed strain gauges
Outcomes
- Graphene successfully incorporated into bike frame to increase its strength
- Feasibility study demonstrated the potential measurement of strain from an embedded gauge, and identified areas where further development work is required
![](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/achievements-graphene.jpg?w=1920&h=1080&q=60&fm=jpg&fit=crop&dm=1559219172&s=660b6e78c00a51f0db60f60c4bcb8a47 1920w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/achievements-graphene.jpg?w=1120&h=630&q=60&fm=jpg&fit=crop&dm=1559219172&s=7c62b034a55fe312a67ce96a1d327bfc 1120w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/achievements-graphene.jpg?w=800&h=450&q=60&fm=jpg&fit=crop&dm=1559219172&s=df68bc36fb127da19ab71d3e9771922c 800w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/achievements-graphene.jpg?w=1600&h=900&q=45&fm=jpg&fit=crop&dm=1559219172&s=e27453f2074f47d6b9ce62afa0efe164 1600w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/achievements-graphene.jpg?w=480&h=270&q=60&fm=jpg&fit=crop&dm=1559219172&s=39cf52927f73b5323bd771355875a0a9 480w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/achievements-graphene.jpg?w=960&h=540&q=45&fm=jpg&fit=crop&dm=1559219172&s=7c09e48bbf63fa1d410810f5c55836a4 960w)
The challenge
In the Tour de France, professional cyclists traverse flat terrain at around 25 mph on custom-designed ultra-light racing bikes. The e‑bikes developed by Evari Bikes can reach speeds of up to 30 mph by incorporating a battery and motor, however these also add considerable weight. It is therefore important, given the load and speed, to construct a bike frame that is strong to ensure a safe product for everyday commuters to ride.
Impregnating graphene into the bike’s carbon fibre epoxy resin composite frame is a viable means of increasing strength with minimal increases in weight. However, the handling and analysis of graphene materials remains out of reach for many start-ups who lack the necessary scientific expertise and specialist facilities. Embedding strain gauges into the bike frame is also a technically challenging prospect, but would help to prevent injury to users should the bike frame develop a defect.
How CPI helped
Through the IMPACT project, which is funded by the European Regional Development Fund (ERDF), Evari Bikes began their partnership with CPI in 2019, in order to explore how graphene could be used to strengthen the frames of its e‑bikes. CPI’s expertise in securing funding was leveraged to obtain grants from the European Union and regional governments, and CPI then began a project to develop a graphene formulation that could be successfully introduced to the carbon fibre epoxy resin bike frame. CPI successfully introduced graphene evenly throughout the resin, helping to ensure uniform strength throughout the frame. A series of initial impact tests were also carried out to analyse the benefits of the new frame material.
CPI then carried out a feasibility study on embedding screen-printed strain gauges into the e‑bike frames. CPI’s previous experience with printed electronics has shown that screen-printed gauges fabricated using carbon-based inks demonstrate the fastest response to the application of strain and subsequent relaxation. Four strain gauges were selected and embedded by vacuum infusion into a carbon fibre, epoxy resin composite, which were then analysed to determine their strain response. The work demonstrated that embedding the strain gauge in the composite provides additional conductive pathways and effectively short circuits the devices. This is likely due to the inherent conductivity of the carbon fibres. CPI identified further avenues for developing these strain gauges so that they can be successfully embedded into future products from Evari Bikes.
Related
Technologies
Markets
![](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/printed-electronics-screen-printing.jpg?w=1920&h=1080&q=60&fm=jpg&fit=crop&dm=1559216756&s=5b39090540c7fc05cf4c5d3d022070cb 1920w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/printed-electronics-screen-printing.jpg?w=1120&h=630&q=60&fm=jpg&fit=crop&dm=1559216756&s=7d9377d1f3ea1106695180c11dba2eca 1120w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/printed-electronics-screen-printing.jpg?w=2240&h=1260&q=45&fm=jpg&fit=crop&dm=1559216756&s=94230309d0aaadbc5585ebd587b82318 2240w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/printed-electronics-screen-printing.jpg?w=800&h=450&q=60&fm=jpg&fit=crop&dm=1559216756&s=39dab3fec71fc938a721b423c8c5c5d6 800w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/printed-electronics-screen-printing.jpg?w=1600&h=900&q=45&fm=jpg&fit=crop&dm=1559216756&s=60b85176f8bec2c92c9e1e8069789c55 1600w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/printed-electronics-screen-printing.jpg?w=480&h=270&q=60&fm=jpg&fit=crop&dm=1559216756&s=6254eba5b70a2945fbaefd416c6a876a 480w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/printed-electronics-screen-printing.jpg?w=960&h=540&q=45&fm=jpg&fit=crop&dm=1559216756&s=123fa0fdd59cf3086ab0e36569096278 960w)