Tough rotomoulded plastic wheels enhance cargo bike durability

As cargo bike deliveries become increasingly common in urban areas, operators are placing unprecedented strain on bicycle components, particularly wheels. Traditional designs can struggle under heavier loads, leading to frequent failures, disrupted deliveries and rising repair costs.

To address this challenge, plastics specialist igus has developed a new generation of robust, rotomoulded plastic wheels, manufactured as a single piece to improve durability and performance. Building on its experience with the igus:bike which is made from over 90% plastic and around 50% recycled material such as discarded fishing nets, the company has refined its wheel technology through extensive real-world testing.

“During hundreds of test rides and the igus:bike world tour, covering thousands of miles worldwide, we found the wheels to be extremely robust,” says Dave Spence, head of bicycle components at igus in Northampton. “We are now offering these plastic wheels in 24” and 26” sizes as a standalone product, giving manufacturers the opportunity to make their cargo bikes more reliable.” Designed for demanding applications in dense city environments to transporting bulky goods in harsh weather, the wheels offer high load capacity and consistent reliability.

Proven durability under heavy loads

Electric cargo bikes often carry total loads of up to 300kg, placing significant stress on wheels when navigating kerbs, potholes and cobbled streets. According to igus, testing conducted in its in-house laboratory in line with DIN 79010:2020-02 standards demonstrated that the wheels meet these demanding requirements. Each wheel was subjected to a 120kg load on a test rig simulating repeated impact.

“Even after 10,000 kilometres, the wheels continued to operate reliably,” explains Spence. “This should translate into significantly fewer wheel replacements in daily delivery use, offering clear benefits for fleet operators.”

Reduced maintenance and downtime

Traditional spoked wheels require regular maintenance, including spoke tightening and re-centring, adding time and operational costs for delivery services. The igus solution eliminates these issues through its one-piece design, produced using rotational moulding. In this process, molten plastic is evenly distributed within a rotating mould to create a seamless, dimensionally stable component.