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AREVO to Produce 3D-Printed Carbon Fiber Unibody Bike Frame for Pilot E-Bikes

The new EVE9 e-bike from Pilot Distribution Group of The Netherlands features a 3D-printed, carbon fiber unibody frame from AREVO. (Photo: Business Wire)

FRIEDRICHSHAFEN, Germany–AREVO will produce 3D-printed, carbon fiber unibody frames for a new line of e-bikes from Pilot Distribution Group BV, the companies announced at Eurobike 2019 in September. The new frame design from Pilot will be based on AREVO DNATM Digital Composites Manufacturing Technology.

The announcement marks AREVO’s second major customer win in the cycling industry within the last six months. Frames of a different design, announced earlier this year, are currently in volume production at the company’s Milpitas, California, manufacturing center.

“AREVO’s continuous carbon fiber technology is very impressive, as it affords numerous design possibilities and provides excellent strength and durability,” said Pilot’s Arno Pieterse in a press release. “The technology truly is a revolution in composites manufacturing and enables us to offer all the high-performance qualities we envisioned for EVE.”

AREVO’s unique additive manufacturing process leverages patented software algorithms that enable generative design techniques; free-motion robotics for “True 3D” construction; and direct energy deposition for virtually void-free construction. According to AREVO, all are optimized for anisotropic composite materials.

“As this manufacturing technology offers such unique possibilities, it enabled us to redefine the way we design bicycles,” said Bastiaan Thijs of “The technology gave us the ability to create a truly one-piece design, carbon fiber-reinforced, fully-integrated eBike frame for the EVE9. Furthermore, it is truly remarkable that this frame is 100 percent recyclable.”

AREVO ( is a Silicon-Valley-based company seeking to redefine global composites manufacturing through digitization. The company develops technology that uses software, advanced materials, and robotics to enable 3D printing of large, mass-produced composite parts and structures, from bikes to flying cars.

“We thank Pilot for the confidence they have shown in the AREVO DNATM technology, which is unique in the additive manufacturing (AM) world,” said Hemant Bheda, co-founder and chairman of AREVO. “We feel we are making a significant impact in the bike industry and see near-term applicability in other areas of green urban mobility, from electric scooters to e-VTOLs, or flying cars.”

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