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Revolutionizing Everyday Mobility: A Bicycle Industry Manufacturing Case Study

Urban congestion, environmental pollution, and unequal transportation access represent critical issues in today's world. The transformative solution to these challenges is to fundamentally rethink everyday mobility - a turn towards innovative, sustainable, and inclusive transportation solutions. MORE Cargobike team embraced this challenge in 2019 in Berlin, offering top-quality cargo bike boxes to foster a more ecological future and great riding fun.


How are Cargo Bikes Manufactured

In this intricate mobility landscape, also manufacturing mobility plays a vital role. On top of this, providing efficient and high-quality services doesn’t come without challenges. The need for suitable material to ensure water or heat resistance, weight optimization, new design creation, and the constant changes to be implemented, all combined with a shift to sustainable manufacturing, form a complex problem set. This is where MaxResolution3D stepped in, providing a more local and reliable supply chain structure via high-quality 3D printing in series production, fostering innovative and sustainable polymer manufacturing, and supporting MORE Cargobike in the production of the boxes.


Collaboration Births Innovation

Cargo boxes for bike manufacturing in mass production via 3D printing in Berlin at MaxResolution3D and MORE Cargobike

The partnership between MaxResolution3D and MORE Cargobike began with the request and order for specific parts for the exhibition stand at EUROBIKE 2022.

After the fair, it became evident the possibility of a long-term collaboration for a monthly and consistent delivery of polymer parts via additive manufacturing of their cargo boxes, dismissing the myth of 3D printing as a slow and expensive solution or limited to prototyping.



Minimizing Eco-impact Through High Quality Sustainable 3D Printing

Together on the path to sustainability, series production via additive manufacturing has brought numerous advantages both in the manufacturing process and in the end product. In the first place, MORE Cargobike has strongly aligned itself with the United Nations' Sustainable Development Goals (SDGs) when producing the cargo boxes and relies on the integration of people with disabilities in the assembly process. At the production process level, MaxResolution3D's on-demand service eliminates waste through overproduction and significantly reduces the ecological footprint, as the components are transported from Southwest Berlin to Potsdam over extremely short delivery routes. The full potential of 3D printing for sustainability in the supply chain becomes apparent here


Series prodcution of cargo boxes via 3D printing fro bike industry at MaxResolution3D Berlin

Product-wise, through additive manufacturing, the partners tested and tweaked material, weight, resistance, and finish, adapting fluid changes in design. The prototyping phase showcased the brilliant potential of LSPc technology, with each iteration leading to an improved version. All alternatives were considered and thanks to the speed of such technology we ultimately settled with EVONIK RG3101, reduced the weight of parts from 20g to 7g, ensured water and heat resistance, and implemented the design with ergonomic adjustments. Consequently, series 0 was produced and implemented at the DRG Behindertenwerkstatt.


50 Sets per month in just three business days

At the current date, MaxResolution3D is the monthly service provider for series production of the previously discussed cargo box parts. The availability of on-demand orders and the agreement of reliability have allowed MORE Cargobike to increase quality, production and sustainability of the process, making it one step closer to the creation of a new everyday mobility.


Are you interested in sustainable solutions and exploring a revolutionized supply chain? Feel free to comment, share, or drop us a message for more information.

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