Reversible Induction-Joined Thermoplastic CFRP–Titanium Bike Frames for Circular High-End Sports Equipment

This presentation introduces a novel, fully repairable bicycle frame concept combining thermoplastic CFRP tubes with additively manufactured Ti6Al4V lugs. Using adhesive-free induction joining, the polymer matrix is locally melted and mechanically interlocked with laser-structured titanium surfaces, achieving joint strengths above 50 MPa. The reversible process allows damaged components to be separated and replaced, significantly extending product lifetime. By integrating recycled carbon fibres and thermoplastic matrices, the design demonstrates a viable pathway toward high-performance, circular composite structures.