Fenix Composites CFRTP Road Bike Featuring Lugged Frame Resolves Repairability Challenges
•February 18, 2026
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Why It Matters
The technology proves that high‑performance bike frames can be both lightweight and circular, reducing replacement costs and carbon emissions while setting a new benchmark for sustainable composite manufacturing.
Key Takeaways
- •CFRTP frame uses induction-joined titanium lugs, no adhesives
- •Reversible joints enable component replacement, extending bike life
- •Joint strength reaches 53 MPa, supporting 3 kN load
- •Energy cost per joint under €0.003, 2.7 g CO₂eq
- •Replacement part cost cut 47%, carbon footprint down 49%
Pulse Analysis
The rise of carbon‑fiber‑reinforced thermoplastics (CFRTP) is reshaping high‑performance cycling, and Fenix Composites’ latest frame showcases the material’s potential. By leveraging 3D‑printed titanium lugs produced through cold metal fusion, the company sidesteps traditional surface‑treatment steps, allowing a naturally rough interface that bonds securely under induction heating. This approach not only trims manufacturing complexity but also aligns with broader sustainability goals, as the process consumes a fraction of the energy required for conventional adhesive bonding.
From an engineering perspective, the frame’s reversible joints deliver a median strength of 53 MPa, sufficient to handle a 3 kN tensile load across a half‑meter strut. The topology‑optimized load‑introduction components weigh just 26 grams, illustrating how additive manufacturing can reduce material usage without compromising performance. Energy consumption per joint is under 0.002 kWh, translating to roughly €0.0022 and 2.7 g CO₂eq, making the joining step virtually cost‑neutral and environmentally benign. These metrics underscore the feasibility of scaling CFRTP solutions in cost‑sensitive markets.
The broader market impact lies in the frame’s repairability. By designing joints that can be disassembled and reassembled, Fenix cuts replacement part costs by 47% and lowers associated carbon footprints by 49%. This circular‑economy model addresses a long‑standing pain point in the bike industry—expensive, non‑recyclable frames—while offering a blueprint for other sectors reliant on composite structures. As manufacturers seek to meet stricter ESG standards, the Fenix prototype signals a shift toward durable, low‑impact composite products that can be maintained throughout their lifecycle.
Fenix composites CFRTP road bike featuring lugged frame resolves repairability challenges
Source | Philipp Huber/fenix composites
Founder of fenix composites (Flensburg, Germany) Philipp Huber’s love and interest in sports have shaped his work with the recycling of fiber composite materials — clearly indicated in his achievement, a JEC Innovation Award for an innovative carbon fiber-reinforced thermoplastic (CFRTP) bike frame.
The bike frame features CFRTP profiles and titanium lugs. It is joined by induction without additional adhesives or fastener elements. Through the reversibility of the process, defective components can be removed and replaced in order to maximize the frame’s life cycle.
“During my thesis, I had the honor of working with many great companies,” says Huber. “Element22 GmbH Kiel, Germany produced titanium 3D prints using cold metal fusion (CMF). Alformet GmbH Dörth, Germany produced laser-assisted tape-wound tubes made of carbon fiber/PA6, and together with hyjoin GmbH Munich, I was able to join these components. This resulted in extremely high-strength and reversible joints 53 MPa, the median of the Weibull distributed strength for the tubular joints.”
Notably, CMF produces a very rough surface. This eliminates the need to laser-structure the surface to create the roughness that allows interlocking between materials. “Only the hole was produced with an allowance and subsequently reamed to compensate for printing inaccuracies,” adds Huber.
Fenix successfully produced a 500-millimeter-long tension strut demonstrator with a tube inner diameter of 30 millimeters (seen in the image above), which will be on display at JEC World 2026’s Innovation Planet, as well as at the Alformet booth (5K122).
The goal was to transfer 3 kilonewtons of tensile force over half a meter. “Thanks to 3D printing, we were able to manufacture topology-optimized components for the load introduction elements that weigh just 26 grams,” says Huber. “This is also due to the fact that the high strength of the joints allowed the overlap area to be reduced to a minimum.”
“During the development of the Lifecycle bike, the focus was on the end of the bike’s life cycle and the issue of repair. The concept is that defective components, such as a broken seat stay, can be removed and replaced.”
Huber breaks down project concept, considerations and process more here.
The energy consumption during joining amounts to a fraction of a kilowatt hour. This means that a connection can be made or broken at an energy cost of approximately 0.0022€ ($0.0026) and 2.7g CO2eq.
“If you compare the costs of joining with the costs of the individual components, you can see that the joining process is negligible in terms of cost,” notes Huber. “This becomes exciting if the CFRTP tube suffers a defect. In this case, the titanium elements can be removed cost-effectively and inserted into a new tube. The cost of the replacement part is reduced by approximately 47% compared to the original part. The carbon footprint is even reduced by 49%.”
Visit Huber’s LinkedIn page for more on his work in composites.
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