First off, a massive thank you to all of you! You’re incredible – 14,779 of our readers took the time to answer up to 50 questions. And as if that wasn’t impressive enough, many of you wrote entire essays in the open text fields! That’s anything but obvious, especially with an average completion time of nearly 20 minutes. Hats off to all of you! So, grazie mille, muchas gracias, tack, merci beaucoup, どうも, dzięki, obrigado, спасибо, hvala, teşekkürler, 谢谢你, شكرا, děkuji, hartelijk bedankt, thanks a lot – and, of course, thank you very much!

What will happen to your answers? It’s simple: you’re our polar star! Your feedback actively helps shape the planning of our future reports and stories, allowing us to cover the topics that matter most to you. Your responses are also invaluable for our group tests, where space for bikes and components is limited. In short, you’ll have a huge influence on how we work.

Now it gets really exciting! Below, we’ll reveal which brands you see at the top in 2025 – whether it’s the makers of the best road bike products or the ones on your wishlist for your next purchase.

The best eMTB brand of 2024

The best eMTB brands of 2024 in detail

How are the results determined? It’s simple: in our reader survey, we asked which brand you think builds the best bikes and which one tops your shopping list. As a global magazine, we took the opportunity to analyse the feedback from our German-speaking and international readers separately – and uncovered some truly fascinating differences along the way.

Your next eMTB

Best brand of 2024: Parts and accessories

A great bike is more than just the sum of its parts – that much is clear. But even the best bike is only as strong as its weakest link. So, which brands deliver the absolute best products? Just like with complete bikes, we’ve also analysed the votes for components and accessories separately from our German-speaking and international readers. The result? Some categories show fascinating consensus, while others reveal clear differences between markets. The “Best Brand” title went to the brands that garnered the most votes overall – regardless of the language and region. Want the details? Take a look for yourself!

The lucky winner

One of the reasons we love our reader survey so much? Not only does it help us get to know you better but also gives us the chance to surprise you with fantastic prizes! Together with our giveaway partner ROSE, we raffled off a Trance X Advanced E+ Elite 0 | V2 worth € 10,499 among all participants. Our lucky winner Janine has been notified.

Those were the Best Brands 2024! Don’t feel represented here? Then sign up for our Newsletter to make sure you don’t miss the next reader survey!

Der Beitrag What are the best eMTB brands of 2024? erschien zuerst auf E-MOUNTAINBIKE Magazine.

Do you know that feeling? Rather than suffering your way through a sad cup of flat white from your colleague’s cheap coffee maker, you smile politely and say, “Uh, today’s tea day for me” just to avoid regretting every sip later? If you can relate, you’re probably already deep into the coffee game. Whether you’ve been at it for ages or just started, the questions on your journey to the perfect brew at home are always the same: Which method suits me best – espresso machine, Bialetti, or filter coffee? Which beans are right for me – Fairtrade, organic, or from your local roaster? Why does my espresso taste so sour, as if someone poured vinegar into the water tank? And seriously, how do I nail that wonderfully creamy milk froth that baristas whip up in no time at my favourite café?

After countless brewing sessions, espressos, frothing attempts, and a pile of cash spent on a solid setup, some of us are ready to dive even deeper into the wonderful world of caffeine, and the questions get more refined: which high-end workshop can take my La Marzocco espresso machine to the next level, visually speaking? Does a € 3,000 grinder extract even more from my favorite beans from the local boutique roastery? Or is it all bollocks? Well, design is a matter of taste – literally. And dreams don’t always have to remain dreams.

As passionate coffee lovers – and you’re probably too, if you’re still reading – you’ve likely asked yourself one or two of these questions already. Is that right? Then it’s time to get excited: we’ve been on a quest for answers, hunting down the best coffee and the most intriguing products in the world of black gold. And we’ve discovered: not all coffee tastes the same, and latte art is far from the only artistic creation in this magical world. Most importantly, we’re eager to share our growing knowledge with you. Our big DOWNTOWN Coffee Special is packed with strong tips for beginners and enthusiasts alike, helping you get the most out of your coffee. No matter what level you’re at, we’re squeezing out a little more for you and diving in together. Even if your favourite café gets a bit jealous, we’ll give you inspiration for your “daily dose of caffeine,” sharing insights and secrets that are usually well kept behind closed café doors. Ready for your best coffee yet? Our collection of coffee stories, reviews, and tips & tricks is growing alongside our knowledge, so it’s definitely worth checking back in regularly. Let’s go…

You can find the full test at our sister magazine DOWNTOWN.

Der Beitrag Of dreams and fluffy creams – What to expect in DOWNTOWN’s Coffee Special erschien zuerst auf E-MOUNTAINBIKE Magazine.

Enjoy the impressions – and if you’re at the Eurobike on the visitor days: come by! We are in Hall 12, Stand B03. It’s worth it, we promise! The code word for the best coffee at the fair (at our stand) is: I love DOWNTOWN.
See you there!

Der Beitrag From Croissants to Cargo Bikes: Discover the Best at Eurobike! erschien zuerst auf E-MOUNTAINBIKE Magazine.

Taiwan is always worth a visit– though it might not be the first destination that springs to mind when you’re booking a holiday! Max, one of the two founders of the E-MOUNTAINBIKE magazine, and Manne, his dad, also had a completely different picture of this country, far from the reality. The small island state lies a mere 180 kilometres from China’s shores, and it’s a real industrial powerhouse, where some of the biggest manufacturers of the cycling industry develop and produce their goods. In other words, Taiwan is the beating heart of the bike world, and the birthplace of modern production expertise. That was reason enough for us to pay a visit to the bike mecca, accepting the invitation of one of the largest dropper post manufacturers in the world: LIMOTEC. Like many more well-known companies such as GIANT, MERIDA and MAXXIS, LIMOTEC have one of their production facilities in the suburbs of Taichung, Taiwan’s second largest city, with a population of 2.8 million. Unlike many other bike companies, however, the dropper post colossus also has its headquarters here, albeit right in the centre of Taichung. From here, Manne and Max set off for the factory, which is around 30 minutes away.

A warm welcome

The first surprise awaits you at the entrance: rather than the usual sterile concrete, you’ll find a lovingly designed pond, which was built according to the principles of feng shui. Manne and Max are greeted by plant manager Erik Cheng and Kelley Liao, Limotec’s Sales Associate Manager. The two receive Max and Manne with the same warmth and politeness that is notable all across Taiwan, along with the same pride for their country and its innovative strength that shines through again and again throughout this exclusive factory tour.

Since their establishment in 2018, LIMOTEC have become one of the world’s biggest manufacturers of dropper posts and suspension seat posts. According to Manne and Max, the Taichung plant has a production capacity of one million units per year. However, production is currently not running at full speed due to the excess of demand during the Corona era, which led to overproduction and weakness in net sales – and the acutely difficult global political panorama also plays a major role. So far, LIMOTEC have primarily acted as an original equipment manufacturer (OEM) for entry-level and mid-range bikes from well-known brands like BULLS, CONWAY and MERIDA. However, we have also seen and tested the Taiwanese brand’s dropper posts on some top-tier bike models, like the MERIDA eONE-SIXTY 10K – although MERIDA put their own label on it. LIMOTEC is still an exotic player in the aftermarket, but wants to get much more involved in the future. In any case, their vast portfolio includes everything from affordable dropper posts for city bikes to an electric seatpost, which should also cut a fine figure on the most premium mountain bikes. We at E-MOUNTAINBIKE magazine have already had the opportunity to test a prototype of their flagship dropper post, the LIMOTEC E1P – you can read the full review here. LIMOTEC claim to be on a par with the segment’s top dogs, like FOX and RockShox, both in terms of quality and features, albeit at a much more attractive price. With this approach, the dropper post manufacturer wants to become increasingly prominent in the near future, especially in Europe and North America, and also play a major role in the aftermarket. We’re excited!

A comprehensive portfolio and high level of vertical integration

Manne and Max are given an overview of LIMOTEC’s product diversity right from the start of the factory tour. On a prominently positioned display, there are 9 different dropper posts and suspension seat posts. From classic droppers posts (with and without remote), to combo suspension droppers and electronic models, LIMOTEC have the right seat post for every occasion – and they’re all available in a wide range of diameters and travel options, for every type of bike: city, trekking, gravel, MTB, eMTB, e-SUV. There’s one special feature that all LIMOTEC seat posts models share: they’re all prepared to take an internal power cable for a tail light, which draws its power directly from the e-bike’s main battery

As Max and Manne stroll through the production plant, they quickly realise that LIMOTEC do a whole lot more than just bolting together third-party components. The entire manufacturing process takes place in-house, from the aluminium blanks right the way to the finished seatposts. The Taiwanese manufacturer also produces a range of remotes, and only the cartridges are sourced externally. Needless to say, Limotec’s R&D team is based at the Taichung site too, where a total of 60 people are currently employed.

We manufacture all the components for our seat posts ourselves. We only source the cartridges externally and buy them from a specialised company. – Erik Cheng, Plant Manager at LIMOTEC.

The highlight of their current seatpost range is without a doubt the LIMOTEC E1 Memory, an electric dropper with adjustable travel that allows you to program different saddle positions – a bit like the driving position memory system of a car. The dropper is powered directly by the ebike system, and Manne and Max learn that LIMOTEC are planning significantly more extensive integration into existing drive systems than has previously been seen on the market, especially in the ebike sector.

Strict quality control

Just like production, the entire quality control process takes place at the Taichung site. In their in-house test laboratory, LIMOTEC simulate real-life scenarios with water and sand to test the sealing and tolerances. In addition, to assess durability and material fatigue, the droppers undergo an additional test with 100,000 loading cycles at 1,850 N, which is meant to simulate the stresses applied by a 180 kg rider – quite an extreme load scenario. Only when the dropper has passed these tests can an employee send it to the packaging department – and perhaps it will land on your next eMTB.

Only when a dropper post has passed all the tests with flying colours is it allowed to leave the factory. – Kelley Liao, Sales Associate Manager

Our conclusions about our LIMOTEC factory visit

Smoggy factory landscapes, old-school punch time clocks and grubby blue overalls – this is how many of us still imagine a production facility in the Far East. During our visit to LIMOTEC, we’ve had a completely different experience: high-tech, cosmopolitanism and impeccable politeness. It’s quite remarkable what this company has achieved in just over 6 years, and the innovative strength it displays. LIMOTEC is a modern company throughout and epitomises the flair of the Taiwanese bike industry – very different from what we might imagine in the West.

Facts and figures about LIMOTEC

LIMOTEC is a Taiwanese manufacturer of bicycle components with headquarters in Taichung City, Taiwan. Founded in 2017, LIMOTEC initially started producing bicycle frames. Their biggest customer is the Accell Group (the company behind brands like Haibike, GHOST and Winora). In 2018, they started producing their first dropper posts in the suburbs of Taichung. LIMOTEC also has three other production sites in China. The German branch is located in Bad Nauheim, where a small team takes care of design and OEM support.

For more info, visit LIMOTEC’s Website.

Der Beitrag Welcome to Taiwan – Visiting the headquarters of dropper post manufacturer LIMOTEC erschien zuerst auf E-MOUNTAINBIKE Magazine.

Ceteris paribus – most of us will have encountered this Latin phrase in maths or physics class, though you might not remember it. It means “all else being equal”. What happens in a complex system when all conditions are fixed and you change just a single variable? Ceteris paribus is crucial for scientific experiments, in order to determine the isolated effect of one variable.

The ceteris paribus assumption doesn’t exist in the ebike industry, or rather: not yet. As eMTB editors, it is our job to fully understand and evaluate ebikes as complex systems, and to convey their unique characters to our readers. A direct comparison of individual parameters, like the motor, is neither possible nor is it necessarily expedient. Our eMTB and motor group tests regularly emphasise that a motor is only as good as the bike it’s in. But now SIMPLON have stepped onto the scene with the Rapcon and a broad choice of motors to choose.

Three motors, four bikes, one recipe for success – The SIMPLON Rapcon

The premium Austrian bike brand is a permanent fixture in our group tests and the group tests of our sister magazines. The SIMPLON portfolio includes a wide range of analogue and electric mountain bikes. The bikes can be built to your liking using the in-house configurator, so almost no SIMPLON is the same.

But you can also use the configurator to build four almost identical SIMPLON mountain bikes, with the only difference being the motor and its corresponding hardware.

The gravity-focused SIMPLON Rapcon is available both as an analogue mountain bike and as an eMTB with a TQ-HPR50, Bosch Performance Line CX, or most recently, Pinion MGU E1.12 motor. We’ve pitted it against the best MTBs and eMTBs in a variety of configurations and numerous tests, but never against itself. How does the bike and its handling differ if you only change the motor system, and are there other unexpected differences?

What is the difference between the Rapcon, Rapcon and Rapcon, and which is the best Rapcon?

Before getting to the practical part of our ceteris paribus experiment, we must define the variables. That means laying the hard facts of the four Rapcons and their different motor systems on the table. Starting with the prices, the analogue SIMPLON Rapcon is available from € 5,599. The SIMPLON Rapcon Pmax TQ with the TQ-HPR 50 motor starts at € 8,699. You’ll have to fork out at least € 8,999 for the Rapcon Pmax CX with a Bosch motor. And the Rapcon Pmax Pinion has the highest barrier to entry, with prices starting at € 9,999.

The large price differences were reduced slightly once we pimped the test bikes according to our preferences. After upgrading to FOX FACTORY air suspension with a burly FOX 38 fork and FLOAT X2 shock, the first three SIMPLON Rapcons were specced with wireless SRAM GX Eagle Transmission drivetrains. The SIMPLON Rapcon Pmax Pinion doesn’t offer any drivetrain options in the configurator because there’s an integrated gearbox in the motor. Further upgrades like powerful brakes, outrageously expensive wheels, and long-travel dropper posts rounded our test fleet off perfectly.

As tested, with all bikes being specced almost identically, the analogue Rapcon underwent the steepest price increase, ringing in at € 8,614. The TQ variant had the smallest price increase, coming to € 10,365. The Rapcon Pinion dropped down the list, becoming the second most expensive bike at € 11,934. Taking the lead is the Bosch-equipped Rapcon with the limited-edition Bosch Performance Line CX-Race motor, which can be yours for a whopping € 11,984.

The first differences between the individual motor systems already show up in the configurator. The TQ system offers the least room for configuration. A 160 Wh range extender for € 620 is the only motor system upgrade available. Regarding the main battery, remote, and display, the TQ system is about as indulgent as Henry Ford when it came to the colour of the Ford Model T: “You can have it in any colour, as long as it’s black.” The permanently integrated 360 Wh main battery, HPR Display V01, and remote are mandatory. There are no other options besides this.

With the SIMPLON Rapcon Pmax CX, on the other hand, the Bosch parts catalogue opens up a wide range of remotes, displays and batteries to choose from. The Rapcon CX is available with either a 500 or 750 Wh battery. We opted for the larger model for an extra € 330. Therefore, we didn’t go for the 250 Wh range extender, which would have cost us € 475 extra. The stand out feature of the Rapcon CX is that you can choose between the Performance Line CX motor and the CX Race variant for an additional € 550. We get weak at the sight of the grey housing and red accents, compelled to choose the race-proven model.

The Rapcon build with the Pinion MGU motor obviously has no drivetrain options in the configurator, though you’ve got a choice of three display and remote combos. One of the most noteworthy features of the motor system, which was created in cooperation with FIT, is the choice of battery sizes. The smallest main battery starts at a considerable 720 Wh capacity. For € 200 more, you can get the bigger battery with an insane 960 Wh (only on sizes L and XL). You can top that up with another 470 Wh with the € 780 range extender, which attaches to the down tube. With a capacity totalling 1,430 Wh, you won’t have to worry about charging until the next summer solstice. We went for the more reasonable “small” 720 Wh option.

Handling and maintenance – How time-consuming and labour-intensive are the four SIMPLON brothers to maintain?

How do almost € 43,000 worth of test bikes weigh up on the scales? The analogue SIMPLON Rapcon can be picked up and weighed with one hand, coming in at 15.86 kg in size M (the same size as all the other models).
The almost identical-looking Rapcon Pmax TQ tips the scales at 19.98 kg. We had to use both hands for the 23.94 kg Rapcon Pmax CX, and the SIMPLON Rapcon Pmax Pinion pushed our 25 kg scale to the limit, weighing in at 25.02 kg.

If you encounter a hike-a-bike section on the trail, it’s relatively easy going with the TQ Rapcon, which can even be shouldered if the push-assist doesn’t help. Of course, the same applies to the analogue Rapcon.

But the weight differences are noticeable when loading and handling the bikes off the trail, too. You can still get the analogue Rapcon on the roof rack on your own. Handling the Rapcon TQ is just slightly heavier. That’s a good thing considering that the permanently integrated battery means you’ll have to carry the bike upstairs into your apartment for charging if you don’t have access to a power outlet downstairs.

The Bosch equipped Rapcon turns out to be a bit unwieldy. Unless you feel like struggling with the bike’s almost 24 kg heft, removing the battery is a somewhat fiddly affair, be it for charging or transporting the bike. The long Bosch battery can only be accessed via the bottom of the down tube. To remove it, you must first remove the skid plate, pull out a plug, push it aside, and then shake the very tight fitting battery out of the frame.

The Pinion Rapcon is even heavier, but at least it’s a bit more user-friendly when it comes to removing the battery. If you have the key at hand, a quick twist of the lock is all it takes to make the battery pop out of the frame. However, if you want to transport the bike with the battery removed, it will be left with a gaping hole in the down tube.

In return, the Pinion Rapcon is easy on the nerves of home-mechanics when it’s time for maintenance. It’s the only eMTB without a chain, rear derailleur, and cassette. All the gears are encapsulated with the motor. According to Pinion, the motor only needs an oil change every 10,000 km. There’s no need to lubricate the belt; it’s enough to spray it down with a hose to wash off the worst of the dirt. The three somewhat lighter, chain and derailleur equipped bikes, on the other hand, require regular cleaning and lubing.

It’s clear that despite their similarities, handling the four Rapcons can be a vastly different experience. But enough of the chit chat, it’s time to head out there and find out how the Rapcon siblings are received by you folks.

Street credibility – How are the different SIMPLON Rapcons received by the bike community?

If you approach a group of analogue riders with either the analogue Rapcon or the Rapcon Pmax TQ, you will be welcomed with open arms. SIMPLON have integrated the TQ-HPR50 system so seamlessly that it’s hard to distinguish from the analogue model.

The motor itself is whisper-quiet and offers such natural feeling support that you can cruise along with a group of analogue riders without getting noticed.

The Bosch powered Rapcon Pmax CX is much less discreet. Although SIMPLON have done a neat job of integrating the motor, the oversized tubes have eMTB written all over them. At the latest, the cat will be out of the bag once you leave the rest of the crew behind in a cloud of dust with just three pedal strokes.

It also makes it difficult to agree on a route to the trailhead. While analogue riders and the stealthy Rapcon Pmax TQ – which has infiltrated the group unnoticed – will prefer sparing their energy on the way to the trailhead by taking the service roads, the Bosch rider won’t want to pass up any climbing challenges along the way, constantly making small detours to find the most technical ascent.

Although the greyish and somewhat prominent CX-Race motor will draw appreciative glances amongst full-power eMTBers, it won’t help you make friends with analogue and light eMTB riders due to the considerable performance gap.

When the Rapcon Pmax Pinion rider joins the group, the first question they’ll hear is whether they’ve chosen the European route or will rather be crossing the Sahara as they circumnavigate the globe. Bikes with Pinion gearboxes and belt drives are very popular amongst long-distance riders, and that just makes this system really stand out from the crowd. Thanks to the massive battery, the capacity of which can almost be doubled in the configurator, the Pinion Rapcon further exudes slightly more expedition vibes than its sportier Rapcon siblings. The Rapcon Pinion is also more noticeable on the trails than the other eMTBs. Not because of a slapping chain, which it doesn’t have, but due to the slightly louder hum produced by the motor and the gearbox, especially in the lower gears.

SIMPLON did a great job of integrating the Pinion MGU E1.12 motor system, but as with almost all Pinion MGU bikes, the Rapcon Pinion has a beefy look. It’s the only ebike in the group with ventilation slots on the head tube, supplying the battery with a stream of fresh air even on the hottest rides through Death Valley.

But what do you care about the superficial differences and what others think? Ultimately, what really matters is that the eMTB appeals to you. With the Rapcon series, SIMPLON pursue a unique concept that must suit your riding style.

“Same-same, but different, but still same” – The subtle, hidden differences between the four Rapcons

SIMPLON would not be SIMPLON if the Austrian brand didn’t make slight adjustments to the frames in ways that go beyond the integration of the various motor systems. So, apart from the motors, the bikes aren’t quite the same, which you’ll see when looking at the geometry. Strictly speaking, this means that the ceteris paribus assumption doesn’t apply. However, they all follow the same concept.

The Rapcon recipe is all about finding the perfect balance of composure and agility, resulting in maximum downhill performance – across all frame sizes. Therefore, SIMPLON adapt the chainstay lengths and the progression, including the rear kinematics, to suit the various frame sizes.

The geometry figures of the four motor variants already hint at their gravity intentions. The analog Rapcon and the TQ Rapcon are virtually identical. The Bosch offshoot requires just small adjustments to the frame geometry details.

The Pinion variant, on the other hand, is a little more of an outlier. It has a minimally steeper head angle, a static chainstay length – the longest of all – and a longer wheelbase compared to the in-house competition. For those who love numbers, we’ve gathered the geometry figures of our four test bikes and put them into the following table. Enjoy:

Due to the steeper seat tube and head tube angles, and the longer rear end, the Pinion Rapcon’s centre of gravity should theoretically be further forward than on the other SIMPLON Rapcon eMTBs. The weight of the rear derailleur and cassette is also eliminated, reducing the unsprung mass at the rear. These components are integrated into the Pinion MGU E1.12, further shifting the centre of gravity forward. According to SIMPLON, the proven Rapcon linkage performs even better on the Rapcon Pmax Pinion. We conducted our own tests, and encountered both subtle similarities and striking differences.

Eeny, meeny, miny, moe – Which system suits you?

For our ceteris paribus group test, we chose the incomparable trails and atmosphere of Girona in northeastern Spain. There, the analogue, Bosch, Pinion and TQ SIMPLONs already garnered a lot of street credibility on route to our test track.

The SIMPLON Rapcon Pmax Pinion leaves the biggest impression on the transfers. It has the plushest suspension of all Rapcon variants, offering the most long-distance comfort. Thanks to the powerful Pinion MGU E1.12 system, you can get shuttled through the countryside without breaking a sweat, and the semi-automatic shifting does the rest.

We compared the efficiency of the four “motors” on a not entirely representative test-loop of approximately 12 km, covering 550 vertical metres. To avoid wasting time, we only used the highest support modes. The three ebikes completed the loop hot on each others’ heels, and all of them were back at the start line after 50 minutes at the most – and let’s just say there’s little point including the analogue model at this point ;).

The fuel gauge on the Rapcon TQ dropped to about a quarter, using up 73% of the battery capacity on our test loop. For the sake of simplicity, we can therefore say the TQ motor consumed around 270 Wh, though the percentages don’t equal watt-hours one-to-one. In the aggressive Race mode of the Bosch Performance Line CX Race motor, the Bosch Rapcon drained a good 40% of the battery, with the display still showing 59% remaining capacity, using 300 Wh of the 750 Wh tank. The Pinion motor in the Rapcon Pmax Pinion proves to be particularly suitable for long distances, only treating itself to just under a quarter of the battery capacity, according to the display. It drops to 75%, which corresponds to a consumption of 180 Wh from the 720 Wh battery, assuming our simplistic 1:1 calculation. As always, battery consumption is heavily dependent on the riding style and the rider (weight), making it difficult to replicate. As with any US car advertisement, this all comes with the following disclaimer: “your mileage may vary”.

The analogue SIMPLON Rapcon completes our test loop only as fast as you’re able to pedal, of course. However, it should be noted that it climbs impressively for such a capable, gravity-focused bike. The rear suspension strikes a good balance between efficiency and sensitivity, pedalling without bobbing too much yet offering plenty of traction on steep, technical climbs. Other enduro bikes could learn a thing or two from the SIMPLON Rapcon.

Only the ground clearance is somewhat limited on the analogue Rapcon: it has a relatively low bottom bracket as is, and it’s the only bike on test with 170 mm cranks, which increases the risk of pedal strikes. The three ebikes don’t need the extra leverage to generate propulsion, relying on stubby 160 mm cranks.

The SIMPLON Rapcon Pmax TQ feels very similar to its analogue sibling going uphill. The very natural assistance and quiet operation of the TQ-HPR50 motor simply makes you feel like you’ve got super strong legs, rather than feeling like a motor is pushing you uphill. The respectable climbing qualities of the analogue Rapcon, coupled with the support from the motor, gives you the confidence to tackle even the most technical ascents. But it doesn’t get up the climbs as effortlessly as the Bosch Rapcon, for example. To extract the maximum power from the TQ-HPR50 motor, you must pedal at high cadence, which proves to be challenging on very rough terrain since the bottom bracket is as low as on the analogue Rapcon.

While the analogue Rapcon and the TQ Rapcon claw their way up the mountain like Alex Honnold, the SIMPLON Rapcon Pmax CX with the Bosch CX Race motor is the mountain goat in the quartet, conquering the summits in a gallop. The incredibly responsive and powerful motor catapults the CX Rapcon up every climb. The long sustained assistance lets you maintain your momentum while keeping the cranks horizontal. That way you’ve got more ground clearance and are able to conquer obstacles with ease. There’s no risk of the motor grinding to a halt on a long climb, even if your legs get tired. The smooth SRAM GX Transmission drivetrain on our test bike also provides a wide range and pleasant gearing increments for technical climbs. Furthermore, if you approach a climb in a gear that’s too high, it will reliably shift into an easier gear even under high loads, without feeling like you’re splitting the rear derailleur in two.

We were hoping for a little more from the SIMPLON Rapcon Pmax Pinion on the climbs. Although it’s just as powerful as the Bosch counterpart on paper, it can’t keep up with the CX Race motor in terms of actual power delivery and the sustained response. Even the ample traction generated by the rear end can’t help it keep up with the Bosch-powered Rapcon. The internal gearbox offers a wide gear range and lots of torque in the low gears. However, this is not as directly linked to the pedalling input as with the Rapcon CX. The shifting also takes some getting used to compared to the bikes with derailleurs. The Pinion gearbox times the shifts itself. When shifting gears, the cranks spin freely for about an eighth of a turn, which can throw you off balance and mess up your timing.

The excellent balance of all four Rapcon ensures intuitive and confidence-inspiring handling on the descents. Nevertheless, the analogue and TQ Rapcons outperform the two full-power eMTBs on the descents. Neither the CX- nor the Pinion-powered Rapcon can keep up with the agility and liveliness of the two lighter models. While the two “big” eMTBs can make you doubt whether you’ll clear certain gaps, their lightweight siblings almost let you hit any jump without first gauging the distance.

There are some differences between the Rapcon TQ and the analogue model, nonetheless. The analogue Rapcon sets the bar in terms of agility, whereas the TQ Rapcon is a bit more composed and slightly less flappable in the air – the additional weight does have some benefits.

If you plunge headlong down the trail on any Rapcon, all four (e)MTBs have enough reserves to forgive overshot landings or missed lines. Blasting over roots and ploughing through rock gardens, the Rapcon family offers loads of traction and stability, thus instilling you with high levels of confidence. Only the somewhat sluggish Pinion SIMPLON has a hard time keeping up. It has the softest suspension of all four models, and the rear wheel sticks to the ground. But the more front-heavy Pinion Rapcon tends to dive deeper into its travel when braking before the corners. In extreme situations, this can make the front wheel wash out, whereas the other three contenders can navigate the tightest corners.

Even if the four SIMPLON Rapcons seem like quadruplets at first glance – apart from the motors – the Pinion Rapcon didn’t inherit quite the same sporting genes as its three siblings. In return, you get high-capacity battery options, the plushest, most comfortable suspension, semi-automatic shifting, and a low-maintenance belt drive, making it the best option for touring.

So, which model, or which motor, suits you best? If you had to choose one common denominator to distinguish the handling of the four SIMPLONs as clearly as possible in order to find out which type of rider they would suit, it would be “sporty”. Admittedly, you could argue about whether a capable descender is more or less sporty than one that excels on technical climbs. Nevertheless, for the purposes of this comparison, we’ll say the analogue Rapcon is at the sportiest end of the spectrum, followed by the TQ Rapcon, then the CX Rapcon, and the least “sporty” option being the Pinion Rapcon. The analogue Rapcon is the most demanding, but it rewards active riders with the highest degree of agility. Lack of input doesn’t get punished as much on the full-size eMTBs, compensating for it with their powerful motors. But they also absorb more of your power when you’ve got an active riding style, resulting in a relatively passive handling.

The chicken and egg problem – Does the motor affect the bike or vice versa?

Thanks to four iterations of the supposedly same bike, SIMPLON manage to cover a relatively wide range of use cases. We don’t know if this was their intention.

Even if the basic elements of the Rapcon recipe have been retained, the handling of the four bikes differs significantly. It goes beyond the different motor parameters. The differences are strongly determined by the integration of the motor system, as well as by small adjustments made in order to harmonise the bike’s character with that of the motor. It’s not clear how much the versatile Rapcon platform influences, limits, or favours the performance of the different motors and, conversely, how much the different motors’ characteristics rub off on the bike’s inherent traits. We don’t think we’ll be able to conduct a more direct comparison of the different motors in the near future, either, yet our first attempt still leaves us with many unanswered questions.

If there’s one thing this experiment has shown us, it’s that our mantra can be reversed. Both are true: a motor is only as good as the eMTB in which it’s fitted, but an eMTB can also only be as well-suited for an intended use as the motor fits this purpose. A light-footed mountain bike will be severely limited by a 9 kg motor system, no matter how efficient the pedalling. It would be more likely to lead to an imbalanced feeling bike. And, conversely, no matter how efficient the suspension, a light eMTB won’t be able to compensate for the raw power of a full-size eMTB on technical climbs.

However, this realisation comes with certain caveats because it cannot be transferred directly to any other eMTB, and it could be proven wrong in the coming years. For more meaningful results from a direct motor comparison, we would have to repeat our ceteris paribus experiment with other identical platforms to determine how much the handling of an eMTB is influenced by the motor, and how much by the platform itself. Modern motors can already be tuned so much by the software alone that you could be fooled into thinking that they’re two completely different systems. The smaller, lighter, and more powerful these systems become, the more pronounced this effect will be. So things stay exciting, and the question of which system suits whom is still far from being answered.

You’re unlikely to get any closer to a direct motor comparison than with the four SIMPLON Rapcons. Although the motor has a big effect on the character of each Rapcon, it’s not the only determining factor. Instead of focusing on a motor when buying a bike, you should think more about how you intend to ride the eMTB. Doing so will expand your horizons, and you’ll be more likely to find your dream bike, with a motor and concept that suits your needs.

Visit simplon.com for more information about our test bikes.

Der Beitrag One ebike, three different motors – Which is the best SIMPLON Rapcon? erschien zuerst auf E-MOUNTAINBIKE Magazine.

VanMoof, Cowboy, Angell Bikes – there are countless bike companies vying to revolutionise the future of urban mobility on two wheels, and make the world just a little bit better in the process. Their smart ebikes are packed with connectivity features, to the point that they have more in common with consumer electronics than with bicycles. Others, like Riese & Müller, focus on the hardware: on the quality of their products, and their robust functionality. Digital features are implemented a lot more subtly and only where they offer tangible added value. Advanced bikes from Frankfurt, on the other hand, have committed themselves to innovative manufacturing processes, aiming to play a pioneering role in the circular ebike frame economy. As you can see, there are many different approaches – but which one will save the future?

You can find the complete article in our sister magazine, DOWNTOWN.

Der Beitrag Frankfurt’s mobility pioneers: Advanced Bikes – Innovative, urban, ambitious erschien zuerst auf E-MOUNTAINBIKE Magazine.

Failures and successes: The market for ebike motors has many players and is still growing. However, lots of players have also left the field along the way, with failures and bankruptcies common. And then there is Bosch eBike Systems: the developer of drive systems are not only pioneers in the field of ebikes, they have also played a key role in shaping the market since its very beginnings and have consistently expanded their market position.The Bosch eBike Systems success story also features the fact that the Swabians are voted BEST BRAND in the motors category by our readers, year after year.

If you’re curious about the factors that contributed to Bosch’s success, you’ll find some clues in Robert Bosch’s memoirs. More than a century later, his memoirs still serve as a guideline for the entire Bosch Group. On the subject of competition, the company founder wrote: “In my experience, there is nothing worse for a company that wants to survive and progress in the long term than not having a competitor.” One hundred years after he wrote his memoirs, Robert Bosch’s wisdom still holds true. But there is surely more to success than just competition stimulating the business. To unravel the recipe for success, we ventured to the headquarters of Bosch eBike Systems in Reutlingen, Germany, to get some insights into the behind-the-scenes world of e-motor development.

The ABC of electric motor development

Right from the start, our flying visit to the Bosch eCampus differs from most of our previous field visits. A brief welcome at the reception desk is followed by a bureaucratic process of checking IDs, asking about access rights and obtaining permission to take photographs. The programme includes not only a tour of the trophy cabinet and the wall of exhibits, which vividly depict the company’s history, but also a glimpse of what lies behind the security gates at Bosch. However, we are not granted unrestricted access; we are allowed to visit the development laboratory, the system test bench, the test tracks and a conference room.

As mentioned at the beginning, the ebike industry now boasts an incredible number of motor manufacturers and brands. However, despite the seemingly low barriers to entry, a number of factors play a key role in determining success or failure. While we’re at Bosch, we want to explore possible approaches to successful motor development. At first glance, the new Performance Line SX motor may not appear to be the most innovative, compact or light motor in its category, but it offers many advantages. Some are specific to this motor, such as the balance between minimal assistance and full power, while others are more characteristic of Bosch. So what’s it all about? What is the ABC of motor development? If anyone can make more out of E than just the fifth letter of the alphabet, it’s Bosch.

A as in Analogue bike

If you want to develop an ebike motor, you have to start with something we all love: the analogue bike. Many of us discovered our love for biking on analogue bikes, without electric assistance. That’s why you first have to ask and answer a few basic questions to understand the needs and expectations of the riders. What does an analogue bike offer us and what do we love about it? What can a motor system improve, which individual needs are better met with an electric tailwind, and what should never be compromised by a motor?

In addition to former analogue bikers, there are many other target groups who have only discovered that two-wheeled travel is one of the best ways to explore the world or to get around in everyday life thanks to the electric motor. To get these new riders on board, we need to step away from the analogue bike and ask different questions. What does the e-drive allow that would not have been possible with a purely analogue bike? What are the new requirements, skills and needs of this audience?

As we look at the exhibits from the company’s history with CEO Claus Fleischer, the evolution from analogue bike to ebike becomes obvious. The first prototype, built in 2009, started out as an off-the-shelf analogue bike, which was later transformed into an “analogue bike with an electric motor” through the addition of generous amounts of gaffer tape, cable ties and some extensive tinkering. It is miles away from what we think of as a modern ebike today. Over time, motor system developers and bike manufacturers have understood that an ebike is more than just an electric motor and battery bolted to an analogue bike, and that the needs of different audiences go far beyond hardware. It started with issues like performance and quality, then visual and technical integration into the bike for better design and handling. At some point, the great battery race began, with an irrational, obsessive demand for ever greater battery capacity. This, of course, came at the expense of handling, integration and weight. As a counter-trend, the supply and interest in light eMTBs increased. And the evolution continues: connectivity, usability, digital services and customisation are the buzzwords of the moment.

But that is not all. Some manufacturers, led by Bosch, now offer everything from urban bikes and cargo bikes to all kinds of trekking and SUV uses, adventure bikes and powerful race eMTBs for chasing seconds at international events. The latest creation is the Bosch Performance Line SX motor, which is the closest thing in the company’s portfolio to an analogue bike feel, and is expected to once again pave the way for new bike innovations.

B as in Battery

Next in the alphabet is B for battery. As soon as you learn a little more about the subject, you’ll know: battery ≠ battery. And again, it is much more than just the nominal capacity of the battery that counts. Dimensions, electrical power, clever heat management and, of course, cell chemistry are crucial. We delve into the technical details with battery expert Dr. Vikram Godbole, Senior Product Manager Batteries & Chargers at Bosch. We quickly realise that we’re a bit out of our depth – Vikram really knows his stuff: after all, he has been working on batteries at Bosch eBike Systems for the past 10 years, having previously worked as an R&D scientist in the field and wrote his dissertation on lithium-ion batteries. For Bosch, motors and batteries should be developed in harmony. Yet Bosch’s approach is the exception rather than the rule in the ebike industry. Competitors such as Shimano and Brose also offer their own batteries for their motor systems. However, they leave it up to the bike manufacturers to decide which batteries to use, and also allow the use of third party batteries. This offers pros and cons: on the one hand, wider choice and greater flexibility, but also less control and more fragmented motor systems. Bosch like to develop the batteries themselves, starting at the most elementary level: cell chemistry. To achieve the optimum power and energy density for an ebike battery, cells are not just bought off the shelf, but are developed to Bosch specifications. The development leaps in the early years were particularly impressive: for example, a higher proportion of nickel greatly increased the energy density. The first ebike battery from Bosch had an energy content of 288 Wh and was rather bulky. Today, the PowerMore Range Extender has almost the same capacity at 250 Wh, and the battery itself is no bigger than a drinking bottle.

Of course, the positive development in energy density has not been the exclusive preserve of Bosch; the other manufacturers have also been able to present ever lighter, smaller and more powerful batteries. However, according to Bosch experts, current lithium-ion technology will soon reach its limits, and new battery technologies will have to be developed. With small and lightweight batteries, heat generation and thermal stability can become a bottleneck to the performance of the electric motor system, and the same applies to the motors. Especially in the motor systems of light ebikes, a relatively high load is distributed over smaller and lighter components in the motor and over fewer cells in the battery. As a result, thermal management is a key issue and needs to be handled by an intelligent battery management system. When the motor and battery come from the same manufacturer and their power ratings are precisely matched, as is the case with Bosch, you can imagine the current performance benchmark that is achievable: the small Bosch Performance Line SX motor achieves a peak power of up to 600 watts despite a motor weight of approximately 2 kg and a relatively small 400 Wh battery, which puts it more in the league of heavier full power motors.

Vikram is not only an expert on batteries, but also a product manager for chargers and batteries, and he anticipates another point on our tour of the eCampus: B for building block or modular system. Battery sizing not only affects technical parameters such as motor performance, range, longevity and charging speed. It also affects the overall concept and design of the bike. Size, weight and shape determine how well the battery can be integrated into the ebike and thus the centre of gravity, the layout of the frame and as such the rear suspension kinematics, and ultimately the overall handling. While the first generation of Bosch ebike batteries was very restrictive in terms of design, Bosch’s third generation motor system, the Smart System, offers a variety of battery shapes, which are also cross-compatible with all Smart System motors. For example, there are still external batteries, such as the PowerPack Frame, that can be removed quickly and easily. This is particularly useful for urban ebikers, who can’t always store their bikes near a power outlet so need to take their batteries with them. It also enables concepts such as the race-oriented Lapierre Overvolt GLP III, which has a particularly well-balanced, central centre of gravity and allows the battery to be changed in seconds under the pressure of race conditions. The internal CompactTube and PowerTube batteries, which can be installed in the frame, have battery capacities of 400–750 Wh, providing sufficient energy reserves for most rides: from a short after-work ride to a long day tour. To meet the needs of cargo bikers and long-distance explorers, Bosch is working on the DualBattery system for the Smart System, which is due to be launched in 2024. This will directly double the battery capacity. However, any motor/battery combination from the Smart System can already be paired with the PowerMore range extender with 250 Wh to flexibly squeeze a little more range out of the system. And even for city bike manufacturers who don’t provide a special mounting point for the battery on the frame, Bosch have a solution with the PowerPack Rack: a battery that simply sits on the luggage carrier at the rear.

When asked what is still missing in the Bosch battery cosmos, the answer is “a standardised plug”. This is at the top of the wish list not only of ebikers, but also of manufacturers. The idea is to be able to use a single charger for all ebikes and, if possible, not have to rely on your own brand- and motor system-specific charger on tour. Instead, you use a charging infrastructure with a plug that is compatible with any ebike, for example in cafés in cycling regions, or in mountain huts on an Alpine crossing. This is why Bosch eBike Systems is engaged in the CHAdeMO consortium, which is already driving forward the standardisation of the charging infrastructure in the electric car market.

Sebastian and Simeon join us in our discussion about the modular principle. Before they take us to the letter C, they would like to add Bosch service quality to the letter B. Because the proper ABC of e-motor development includes not only all the hardware spread out on the table in front of us, but also a comprehensive service network that keeps all Bosch ebikes around the globe running. In addition to a guaranteed supply of spare parts, this also includes comprehensive dealer training. One reason why Bosch always comes out on top in the popularity stakes of our annual reader survey is that it is easy to find a local contact. To ensure this, Bosch eBike Systems runs an extensive dealer training programme, with over 17,000 training participants expected in Europe alone this year. In addition, there are 350 shops in Europe that have been certified as Bosch eBike Experts and receive ongoing training. Special tools and software are also being developed for dealers, such as the CapacityTester, which allows the local bike shop to diagnose battery faults, for which other manufacturers require the battery or the entire ebike to be sent in. At the moment, there are very few e-motor manufacturers that have developed a good regional presence, let alone the mammoth task of a global service network.

C as in Control

For the letter C, we have to go through several stations on the Bosch eCampus, explain Sebastian and Simeon. They are actually quite far down the process chain and apply the motor system software to the hardware. In a narrow sense, C stands for control; in a broader sense, it includes communication, configuration, customisation and collaboration. What does that mean? At its best, a good ebike motor knows what the rider is doing. It recognises the riding situation and adjusts its motor power accordingly. At the same time, the motor must react in a predictable and appropriate way so that the rider is not subjected to unwanted surprises. In the first generation of Bosch ebike systems, there were only two arrow buttons to switch between the linear riding modes of Eco and Speed. Everything else had to be controlled by your own input on the pedal. That worked in the days when we rarely rode in technical terrain. But the way we ride eMTBs has evolved. Dynamically changing riding situations leave little time for awkward communication between man and machine.

Since then, Bosch have made great strides in motor tuning and configurability and are one of the leaders in the ebike industry. There isn’t only a wide range of motors, but also a wide range of tuning options that can be loaded onto the ebike depending on the intended use. For touring bikers, for example, the dynamic Tour+ mode continuously adjusts motor power to the environmental conditions and riding style. On the flat, it is designed to provide gentle, battery-saving support to achieve a high range. When you start to climb or get into a strong headwind, the motor senses the increase in rider power and adjusts its own power output accordingly, giving you a smooth riding experience without having to constantly press buttons. The counterpart for sporty riders is the eMTB mode, which regulates motor power over a wide range and is adapted to technical riding manoeuvres such as starting uphill or tackling steps. This allows riders to intuitively control motor power, even in tricky situations where there is no time for pressing lengthy button combinations on the remote. Another example is the Race mode, which has been specially developed for racing and is used exclusively on the Bosch Performance Line CX Race motor. It’s characterised by a particularly direct response combined with brute power delivery, so that professionals with a high level of bike control don’t lose valuable seconds on the trail. Bosch are also applying the experience they have gained in the field of precision motor sensors to other products, thinking beyond the limits of pure motor systems. With the second generation of Bosch’s eBike ABS, for example, the company have a trail-ready anti-lock braking system in their range that gives both ebike newbies and experienced riders more control over their front wheel in critical situations, and thus greater safety.

Despite the already fine-tuned motor characteristics, Bosch leave the final touches to the rider. Each mode can be further adjusted via the eBike Flow app to suit individual needs in terms of power and dynamics. The basic motor tuning process requires five locations, only three of which are on the eCampus. The software programmed in the development offices can first be validated in the in-house system test bench. Without revealing too many technical secrets, we can only say that the Bosch system test bench is state of the art. It has a particularly high level of dynamic control to simulate racing situations and can measure power and performance at several different points on the bike. This allows conclusions to be drawn regarding the precision and performance of the software and hardware, as well as quality control. Which brings us back to the C of Control. The system test bench allows continuous operation from morning to evening and doesn’t complain about overtime if the 40-hour week has already been reached by Thursday noon. But as good as the test facility is, it cannot replicate the human factor. That’s why we’re leaving the building complex on the campus for the first time and heading to the in-house test track.

The Bosch employees need a permit to use the test track. And we need a liability disclaimer. Various obstacles, climbs, trail conditions and curve radii, including elaborate wooden structures, have been built on the test track. The test track is very “nice”, but it doesn’t offer the opportunity to test the most important of all riding characteristics: Fun! For that, we would have to leave the campus and explore the surrounding trails, but with 23 more letters in the alphabet, there is no time to spare. The developers also maintain close relationships with professionals from various ebike racing series. This way, feedback from riders at the highest level also flows into their development.

There is another C in the ABC of electric motor development that Bosch take into account, but which is overlooked by many competitors: C for cooperation and collaboration. It goes without saying that bike manufacturers work together with Bosch and communicate their requirements and wishes. That’s why, according to Bosch, more than 100 well-known manufacturers have opted for a Bosch motor system. Collaboration, however, means something different, which for Bosch eBike Systems is tantamount to a trend reversal. They want to give the manufacturers more influence and take a back seat. As a biker, you will notice this in subtle changes, such as when you open the eBike Flow app and are greeted by a Trek or Cannondale logo instead of a Bosch start screen. Up to now, Bosch have been more dominant in this area. Customers’ loyalty to the bike brand was based on the Bosch motor. In our reader survey, more than 40% of all participants said they were riding an ebike with a Bosch motor and would like to have one on their next ebike. With a more discreet appearance, Bosch want to promote the brand awareness of the manufacturers, which is beneficial for the customers’ loyalty to the bike brand – after all, there is more to the way an ebike rides than just the motor. That makes the manufacturers particularly happy, of course. The question of how Bosch came to change their mind brings us back to our first respondent, Claus Fleischer.

C as in CEO, or Claus Fleischer

Claus has been Managing Director of Bosch eBike Systems since July 2012, in other words he has been with the company almost from the beginning. Talking to him, it quickly becomes clear that he doesn’t fit the classic image of a CEO of a large corporation with only an eye for sales and profit figures. A passionate rider himself, he spends almost every free minute on his bike. Not only does he know the Bosch ebike portfolio inside out, he also has a feel for the needs of the bike community and a real soft spot for the ebike racing scene. Of course, the success of a company can never be attributed to just one person, it always needs a strong team – as the company’s founder Robert Bosch already knew. However, Claus sits at the intersection of the corporate world and the bike world, which sometimes have different views that need to be balanced and reconciled. The process-driven side of the company, the high level of professionalism that goes with it and the rigid process-oriented structures are noticeable at every security gate and checkpoint. If you want to produce quality in series, you need this process-driven approach. But it often causes friction in the more laid-back bike industry. Claus combines both worlds and, together with Stefan Schlie, has successfully turned his own personal passion, Uphill Flow, into a company project: riding fun that not only thrills on the flat and downhill, but also uphill. Not only did they develop the matching motor system, they are also involved in various initiatives, including trail construction to ensure trails that offer riding fun in all directions. He is also highly engaged and actively lobbies at both community and industry levels, whether it’s for ebike and trail legalisation or e-racing sponsorship. Whatever the subject, Claus is someone you can talk to on an equal footing, and who shares the same values as most bikers. But before we get too carried away, Roumen, the product expert for digitalisation and marketing, takes us to the next letter.

D as in Digital Environment

Roumen’s field of expertise is not so easily associated with a physical location, but rather takes place in a virtual space. We are talking about D for digital environment. The first Bosch ebikes were created in the midst of the digital age. However, the opportunities offered by technology and digital tools were somewhat neglected. Connectivity was seen as an add-on rather than part of the product experience. Today we know that it is no longer just about cycling and that the focus is increasingly shifting from hardware to software. For Roumen, it is clear that when you buy a bike with a Bosch Smart System today, you are not only buying the hardware, but also the software with all future updates and a comprehensive service package. The digital environment is increasingly becoming part of the business model, as you can subscribe to additional digital services.

Bosch’s previous digital ebike environment was a private club with a strict doorman. Bosch want to loosen the strict access control and enable more connectivity points for cycling-related services. Well-known fitness and activity tracking providers such as Strava, Komoot or Apple Health will find their way onto the ebike, and other, smaller service providers will follow in time. In addition, a strong digital environment helps to approach the development of motor systems from a user experience perspective. This means, for example, that all motors in the Smart System can be updated over-the-air. Not only will this make life easier for dealers, but it will also enable riders with Bosch motors to keep their bikes up to date and add new features. Many bikers were probably amazed when, after the update in November 2022, the eBike Flow app combined with the KIOX 300 display suddenly had a navigation function.

Another way to enhance the customer experience is a premium service package from a single source. For the Smart System, this means the link to the Bosch ConnectModule. The tracking module, which is concealed within the bike, offers theft detection and alarm functions. This could also form the basis for insurance cover with a replacement option. With the Flow+ subscription service, Bosch already have their own theft protection in the programme, which not only acts as a deterrent but also provides a sense of security.

E as in Electric Motors

You run a few volts and amps through a handful of wire coils, which generate a magnetic field that interacts with the magnetic field of a permanent magnet. Woosh, you’ve created a rotary motion and the ebike motor is ready – or is it? Well, not quite. After our odyssey through the eCampus, it’s pretty clear: to successfully develop an e-motor, all the knowledge gathered from A to D must be carefully examined and integrated into the motor system. Of course, the size of the motor, its weight, the materials used and the laws of physics themselves all impose limits. You can explore these limits to the full or even try to circumvent them in order to develop ever smaller, lighter, stronger and more robust motors. But this is not the recipe for success. The motor hardware is just the base, the motor system gives the character, the software brings the system to life and the service around the ebike guarantees satisfaction for the long run.

If you were to revisit the initial question “What do we love about analogue bikes?” from the perspective of an athletic mountain biker, the following things would be at the top of the list: a sleek, minimalist look; light and nimble handling that provides a natural riding experience; and the direct connection between the rider’s own power and the bike’s propulsion. If you were to design a suitable electric motor and motor system for this type of rider that wouldn’t interfere too much with the look and feel of an analogue bike, you would probably end up with a minimal assist motor. Does it have to be the new Bosch Performance Line SX Smart System? No, there are plenty of other fish in the sea that may be lighter, more compact and easier to integrate. But there are many reasons to choose Bosch, with its holistic approach in quality. And, of course, the fact that the motor, with its peak power of 600 watts, closes the gap between minimal assist and full power motors, making some new and exciting bike concepts possible.

The road to success has been mapped out, and no matter which manufacturer you ask today, Bosch get a lot of things right. This can be attributed to E: Bosch’s many years of experience, another key success factor in the ABC of electric motor development. In 2019, Bosch eBike Systems celebrated their 10th anniversary. In human years, the company hadn’t even reached their teenage years, but in ebike years they were already a veteran in the industry. In 2021, the Smart System was presented, the third generation of the motor system after just 12 years of company history. This shows how fast the ebike market is developing and how much pressure there is to innovate. The way we ride and what an ebike is used for is still evolving. Bike and motor manufacturers also need to evolve, as does the bike community. There is still too much irrational willingness to buy the bike with the highest torque or the biggest battery instead of looking at the whole concept. The Bosch SX motor is a step towards the diversification the market desperately needs. The more diverse the market, the more new applications can be developed, allowing ebikes to evolve in line with our changing riding habits.

E also stands for the end. The End?! Wait, aren’t there 21 letters missing? Well, after a long day at the Bosch eCampus, we came to the conclusion that successful e-motor development is too complex to be captured in the 26 letters at our disposal. The only letter we’d like to add is F for fun, and we’ll finish with this: if you’re having fun riding, the rest of the alphabet doesn’t matter.

Der Beitrag How to develop an ebike motor system?– A visit at Bosch eBike Systems erschien zuerst auf E-MOUNTAINBIKE Magazine.

First off, we want to thank you all again for your participation, engagement and trust! The fact that more than 14,000 bikers around the world answered up to 90 individual questions and provided us with such detailed feedback can’t be taken for granted! All the more so when we consider that the average time to complete the survey was over 20 minutes! In turn, from the very bottom of our hearts: grazie mille, muchas gracias, tack, merci beaucoup, どうも, dzięki, obrigado, спасибо, hvala, teşekkürler, 谢谢你, شكرا, děkuji, vielen Dank, hartelijk bedankt, thanks a lot!

But what exactly do we do with your responses? The results of our reader survey provide significant input into our editorial planning and the future direction of our magazine. It also allows us to select the most relevant brands for our group tests. As much as we would like to review every single bike out here, we can only pick so many. As you can see, our readers really are an integral part of our editorial planning.

Below, you won’t only find out which brands you think make the best eMTB bike products but also who you’ll buy your next eMTB from.

The best eMTB brand 2023

The best eMTB brands 2023 in detail

So how have these results been compiled? It’s really simple: in our reader survey we asked which brands create the best bikes and which brand you are most like to buy. As a bilingual magazine, we made use of the opportunity to analyse data not just from our German-speaking readers but also from the international readers of our English edition. We looked at these separately and it revealed some exciting results.

Your next eMTB

Best Brand 2023: Parts & Accessories

A top-flight bike is more than just the sum of its parts but even the best bikes are only as good as their weakest component. So which brand makes the best products? Just like with the bikes, we’ve compiled two separate sets of data when it comes to parts and accessories, dividing German-speaking and international readers. While there’s common consensus in certain categories, there are stark contrasts to be seen in the brand preferences across others. Printed in bold you’ll find the brand that received the most votes overall – languages and nationalities have no effect on this result. As you can see for yourself, the breakdown of the results is pretty interesting:

The lucky winner

One reason we like our reader survey so much is not just that we can get to know you better, but also that we can surprise one of you with a new bike. This year, together with our partner Haibike, we raffled off a Haibike AllMtn 10 worth € 7,299. One lucky reader, Elmar, already received his Haibike AllMtn 10.

So, these are the best brands of 2023! Not happy with the results? Then sign up for our newsletter so you can make your voice heard in our next reader survey.

Der Beitrag What are the best eMTB brands in 2023? erschien zuerst auf E-MOUNTAINBIKE Magazine.

The idea for the new concept of a cast aluminium ebike came from Emmanuel Antonot, a.k.a. Manu, co-founder of Moustache. His dream was to build a full-suspension step-through ebike using a novel manufacturing process. In doing so, Manu presented the development and manufacturing teams involved with a tremendous challenge. To find out what’s inside the J and how it’s made, we followed the entire production chain through four different companies. Of course, we seized the opportunity to test-ride a couple of the models on home turf while we were there.

Moustache have always been a little different. The French brand have developed and designed a wide range of models, though focusing exclusively on ebikes. From eMTBs to e-SUVs, e-road bikes, and even an e-tandem (WTF?). However, the brand are venturing into new territory with the J: a full-suspension step-through. But that’s not all: the frame is made entirely in France, and instead of a conventional, welded aluminium frame, it consists of two cast aluminium parts – the main frame and the rear end. Both parts are cast in Marseille from European aluminium (plus smaller pieces like dropouts and seat post clamp), then reworked in the French Jura using a CNC machining process, and powder-coated near Strasbourg, before the bikes are finally assembled in Thaon-les-Vosges in the Moustache HQ. These four French stops are the key to significantly shortening the distance of the bike’s production chain and thus its carbon footprint.

From a block of aluminium to a bike frame

There used to be 20 foundries near Marseille, but today the Fonderie du Midi, founded in 1950, is the only one of its kind. The foundry started with the production of Boules balls, but today focuses on the production of helicopter and tractor castings as well as components of France’s high-speed train, the TGV – all in small batches, never resorting to automated mass production. Even though the Fonderie du Midi has a long history in the bicycle industry, casting magnesium forks for Hurrycat, and aluminium bike parts for Vitus, the production of an entire frame was new territory.

The collaboration with Moustache began three years ago. The development of the J-frame initially presented the foundry with a major challenge as it usually only does gravity casting, and there’s a lot to consider with such a large and complex component as a bicycle frame.

The production process starts with raw aluminium, sourced mainly from France and Italy, which is melted down in the Fonderie du Midi. Forming the core of the ebike frame, which must remain hollow, is a positive mould made of sand and resin. This mould is placed between two steel negatives, into which the liquid aluminium is poured at around 800° Celsius. After about 5 minutes, the frame is mostly hardened and a machine presses it out of the mould. The frame is then baked in an oven at 400° Celsius for 8 hours, thereby melting the resin/sand core inside of it and homogeneously annealing the aluminium. Doing so relieves internal stresses and achieves uniform strength. Any remaining sand or excess material is removed before the frame undergoes another 6 hour heat treatment at 550° Celsius. The cast frame is then quenched in cold water to harden. Before the casting is subjected to CNC machining, it’s checked for warping.

The cast frame parts proved to be three times as strong as the required minimum standard in the lab, which is why Moustache offers a 10-year warranty on the frame. The foundry can cast around 100 frames per day.

CNC machining at ELCAM USINAGE

The idea of casting a complete bike turned out to be more demanding than expected – cast surfaces are very rough and not always perfectly uniform, and things like holes for the bottom bracket, steerer tube, or shock mounts can never be cast as precisely as necessary. Therefore, machining is necessary to achieve the final finish. Preparing for the most extensive machining step in the manufacturing process required 1.5 years of intensive development work by all parties involved. These include ELCAM, who are responsible for the CNC post-processing. After the first prototype was cast, ELCAM had to test new approaches as machining the frame proved to be more complex than with other parts. Making matters worse, the castings never come out of the foundry exactly the same, and they have few flat, straight surfaces to use to clamp them in place for machining. As such, ELCAM developed a special clamping device for the Moustache project in order to guarantee consistently accurate machining.

The machining is carried out by a single 4-axis CNC machine. It cuts all the required holes and threads, like those for the shock mounts, without having to realign the frame. The main frame requires 21 different tools and around 55 minutes to machine. It takes another 25 minutes of machining for the swingarm, followed by manual labour to deburr and sand the frame. A high-precision machine then checks the frame tolerances randomly in an insulated, air-conditioned room. All in all, the CNC machining is a very lengthy process.

In order to achieve a precise, uniform end result, the engineers at Moustache and ELCAM had to cooperate very closely. The development team consisted of 2 developers from ELCAM and 5 production employees from Moustache. They were particularly proud of the fact that the frame can be machined in a single operation. Unfortunately, we weren’t allowed to take detailed photos of this step ;).

Colouring in – Powder instead of paint

After CNC machining, the cast aluminium frame retains its rough cast surface everywhere where there is no machining required. This is difficult to cover with liquid paint, which is why Moustache opted for solvent-free powder coating to protect the frame and maintain the look – the rough cast surface remains and the fine powder is capable of reaching all nooks and crannies thanks to the way it’s applied. The Colibru coating company is a subsidiary of Fonderie de la Bruche, where Moustache originally wanted to do the CNC machining. This didn’t work out, but they agreed to take care of the powder coating, nonetheless.

But what are the individual steps involved? First, all holes and threads that shouldn’t get coated are covered or taped off, then the frame receives an acid bath and rinse, to remove any contaminants before coating. All components to be coated are then passivated: this creates a protective layer against corrosion and maintains the electrical conductivity, which is important for the actual powder coating. A negative charge is applied to the frame components, while the paint particles are positively charged. This ensures that the powder clings to the frame components as if by a magnet and really gets in everywhere. It also coats rough surfaces such as those on cast components flawlessly. The powder only adheres to the frame due to the negative charge, but the subsequent baking at 200° Celsius for 15 minutes hardens the powder and virtually fuses it with the frame.

The whole process takes three hours in total, but up to 250 frames can pass through the conveyor simultaneously. Finally, the plugs that covered the important threads and openings are removed and the coating is subjected to a visual inspection before the frames are wrapped back up and sent to Moustache’s headquarters.

Many small components become a large whole – Assembling the Moustache J

Moustache Bikes are based in Thaon-les-Vosges, near Épinal. Moustache are one of the largest employers in this town of 32,000 inhabitants, with around 200 employees, of whom about 80 work in production. The company was founded in 2010, and in 2022 they generated a turnover of 130 million euros and produced 64,000 bicycles. They have enough capacity to produce up to 100,000 bikes per year, and the French brand are striving to expand this even further, with increasing automation of the production lines.

The assembly lines are named after their home town and consist of Thaon 1, 2 and 3. At Thaon 3, the bikes hang from rails on the ceiling and move along the assembly line from employee to employee like on a conveyor belt. Moustache even lace their own wheels – partly manually and partly by machine.

Of course, Moustache also invest a great deal of effort in the development of new bicycles. They have a team of 25 employees involved in product development. The goal of making the J look so simple was a big challenge that was more complex than it might seem at first glance. According to Moustache, the production of a welded step-through ebike from the Far East would have been significantly cheaper than production within France, for example. For the J, they had to set up special testing facilities in order to test the cast frames before getting their official certification, allowing them to increase the test forces beyond the standard. The J frame is up to 3 times stiffer than a conventional welded frame – persisting through figuring out the production process paid off.

From production to the road

Of course, we had to test ride the new Moustache J on its home turf in France. The Moustache J is available in three variants: On, All, and Off (-road). In line with their respective names, the models are specced to cope with different terrain, although the Off was not yet available at the time of our visit. Our journey began in Marseille, at the molten metal origin of the J. Here, the coastal promenade and the mix of modern architecture and narrow alleys invite you to cruise along without any particular destination in mind – which we did, aboard a Moustache J On, and a J All. The hilly coastal landscape around Cassis, 30 minutes northeast of Marseille, is so high above sea level that the Bosch Performance Line motor has its work cut out for it to get us up there. However, the view more than compensated for the tired legs and drained battery.

We also rode around in Thaon-les-Vosges. Here you can cruise along the picturesque Moselle or branch off into the low mountains of the Vosges. For the latter, the Moustache J Off would undoubtedly be the best suited, available from October. But no matter which model you choose, you get a uniquely made bike with a striking look, made entirely in France.

Moustache’s new full suspension step-through ebike stands out from the crowd thanks to its unusual frame and production method, cast from aluminium and made entirely in France. Seeing every step of the production process showed how much development work, passion, and idealism the company have invested into the J project, and the immense effort put into building each individual bike. Chapeau Moustache.

More info: moustachebikes.com

Der Beitrag Moustache J – Following the journey of a cast aluminium step-through ebike erschien zuerst auf E-MOUNTAINBIKE Magazine.

Reliable commuter and cargo bikes during the week – Adventure buddies at the weekend?

From Monday to Friday, they faithfully take us to our workplaces and to the gym, or transport our shopping and children across the city. Commuter, cargo or trekking bikes, fully equipped eMTBs or city bikes with off-road tires – the term SUV eMTBs covers a wide range of different bike concepts that are designed to make our everyday lives more practical, healthier, environmentally friendly, and efficient. As a cargo bike and means of transport to yoga classes or business appointments, they are above all practical. But we were convinced that there is more to it and resolutely grabbed the Riese & Müller Multinker and the Specialized Tero X to take them on an overnight trip into the mountains. Spoiler alert: SUV eMTBs are not just practical, they can also evoke a sense of both excitement and emotion!

A trekking bike and a cargo bike, fully loaded with everything you need for a proper excursion. An overnight stay without having to weigh every gram of luggage, just take whatever you feel like. We left the city of Riva and started our journey of discovery up in the mountains in the hinterland of Lake Garda with two bikes that could not be more different. The make-up of the team was as unusual as the whole idea.

Riese & Müller Multinker

As a cargo bike well-suited for bakery runs, with a very long wheelbase and a good level of comfort despite 20″ small wheels, the Multitinker with the Bosch motor just had to go on the tour with us. Normally used as an urban car replacement, our trip into the mountains was a real challenge for it. But the cargo bike did surprisingly well both uphill and downhill. Kudos! We just need to work on our loading skills.

Specialized Tero X 6.0 eSUV 2023

Unlike the Multitinker cargo bike from Riese & Müller, the Turbo Tero X trekking bike from Specialized is absolutely suited for off-road use, just like the Mercedes G-Class. Even though the fully equipped eMTB was developed especially for everyday use, it does not shy away from rocks and roots. The rear luggage rack with side rails can hold up to 20 kg of cargo and an optional front basket can be attached to carry an additional 10 kg of luggage. We didn’t have the basket with us – so the Riese & Müller Multitinker had to take on the lion’s share of our things.

Adventure with luxury equipment

What haven’t we done to experience adventures and overcome our limits? Mountain biking on risky trails in Rio de Janeiro, diving with sharks on the Burma Banks, crossing the Alps in a snowstorm with the bikes on our backs. And now the absurd idea of turning our urban bikes into off-road warriors, as if they were some kind of Transformers? Whatever! The main thing is to get out of the city, leave everyday life behind and test our personal limits again. Looking at the huge panniers of the Riese & Müller Multitinker, an overnighter seems pretty obvious. After all, surely there’s more to it than just carting kids or the groceries around town. We’ll find out later whether that worked or not. With a permissible total weight of 200 kg, there is plenty of room to spare: A huge tent, camping chairs and a table, all our stuff for the night, as well as a coffee maker, china and, of course, the Aperol for a sundowner.

Unconquered mountain tops and other highlights

We start our tour fully packed with equipment that you don’t necessarily need for camping, but in our case we wouldn’t want to miss out on. Riding our bikes in the mountains requires a lot of stamina and endurance, but aren’t these the qualities you need for an adventure? After all, adventures are nothing more than new experiences that involve an element of uncertainty, risk and anticipation. Discovering new places, overcoming not only your own limits but also those of the equipment you carry. Physical challenge and adrenaline included.

In summary, everything turned out better than expected. The luggage weighs down the rear wheel of the Multitinker and provides the necessary traction – similar to chucking a bag of cement in the trunk of a rear-wheel drive car in the past to make it behave on slippery roads. The battery also holds up well and the motor pulls uphill – better than expected with so much luggage. A little pushing was required, which was made manageable thanks to the integrated pushing aid. Yet our plans failed. The route to the originally targeted mountain top turns out to be too steep, too windy, and ultimately impassable. Who cares, we’re not out to smash any altitude records today! Plan A is cancelled, but that’s okay. We find another hill and go straight for plan B: Take it as it comes! Instead of frantically searching for alternatives and a super Instagrammable photo spot, we pitch our tent where it is convenient. Now the masses of luggage that already caused a stir on our way out of town come in handy. The tent is quickly assembled or inflated and offers ample space for 3–4 people, the camping chairs first create a kind of jigsaw and then a glamping feeling, and we are also well set up in all other respects. The spectacular view and the Aperol we brought along, complete with ice cubes in real glasses, paired with a picture-perfect sunset, compensate for the ascent. In short, we have everything we need to transform our meagre mountain camp into a luxury resort. If you’re looking for a bit more comfort on your weekend adventures, a rooftop tent might be the perfect solution. Be sure to check out our extensive rooftop tent comparison test.

Admittedly, we slightly overdid it with the luggage volume: The bags, especially on the cargo bike, were too full and we didn’t fix the Tero X bags properly, causing them to slide back and forth. Next time we would pack a little more smartly instead of throwing everything that might be somehow of some use randomly on the bike. But what remains is the feeling of having tried something new again. And on bikes that you wouldn’t expect to find here in the first place, but which have proven to be reliable companions in the end.

Bikepacking with SUV eMTBs done differently: Focusing on the equipment and not on the performance. We took three lessons away from our trip into the mountains. Firstly, have the courage to materialize your own ideas and break down the boundaries set by products. Secondly, never underestimate your bike – it has more adventurous potential than you might think. And thirdly, enjoy the view, the sunset and don’t forget the ice cubes for the Aperol!

Der Beitrag Weekend adventure – The underrated potential of e-SUVs erschien zuerst auf E-MOUNTAINBIKE Magazine.

In our “A coffee with…” series, we sit down with fascinating personalities from the world of biking for relaxed conversations over coffee. In each episode, we’ll delve into their lives and ask them some intriguing questions. Join us as we discover the stories behind legends, one coffee at a time.

E-MOUNTAINBIKE:
Before we start one important question: Should life be fast or slow?

TROY LEE:
Both! Life is full of grey areas, and this is no exception. Sometimes we need to slow down and take it easy, while other times we need to rev things up and go full speed ahead. The key is to recognize when we need to switch gears and find the right balance between the two. So don’t be afraid to embrace both sides of the spectrum and enjoy the ride!

E-MOUNTAINBIKE:
Who is Troy Lee? Describe yourself in 3 words.

TROY LEE:
Fast, Slow and Colourful. My world is about racing and colour!

E-MOUNTAINBIKE:
How and when did you start TLD?

TROY LEE:
At a young age, I started customising motocross helmets for a few friends, purely for the fun of it. But word quickly spread, and soon enough, I had other racers lining up to get their helmets painted by me. Before I knew it, I was making money and had to start paying taxes. That’s when the need for a business name arose. My mum stepped in and designed some business cards with the name Troy Lee Designs on them. At first, I thought it was a terrible idea, but in hindsight, it was the best thing that ever happened to me. Thanks, Mum!

E-MOUNTAINBIKE:
Did you foresee this success and that TLD would go into the direction it did?

TROY LEE:
No way! But I’m just getting started. I’m hopeful that there’s still plenty of success ahead of me and the ideas we have. These days, we’re producing a whopping nine different helmets simultaneously, which is a far cry from the one or two we used to churn out. We’re branching out into street and MotoGP, supporting more riders, and expanding our production facilities across Portugal, Italy, Hungary, and Thailand. I am right now with an amazing team of employees and partners. I’ve always believed that if you surround yourself with talented, driven individuals, anything is possible. Let’s keep pushing forward and making great things happen!

E-MOUNTAINBIKE:
What was key to your success?

TROY LEE:
Loving what I do! And surrounding myself with better artists and great people. I always tell my employees: “If I can do that better than you, I have to let you go. Make sure to impress me!”

E-MOUNTAINBIKE:
What did you (have to) learn along the way?

TROY LEE:
I am definitely still learning, but treating all people with respect is one of them. I believe that staying true to what you love and persevering through failures is key to achieving success. When things don’t work out, it’s important to keep swinging and trying again because eventually, they will work out. My personal philosophy is to infuse art and soul into everything I do. When you put your heart into your work, it has a way of working out in the end.

E-MOUNTAINBIKE:
Are you still hands-on? What day-to-day tasks do you (still) enjoy?

TROY LEE:
Yes, of course. My favourite thing is working with my artists and creating safe and premium products.

E-MOUNTAINBIKE:
And what do you don’t like?

TROY LEE:
Undoubtedly, the hardest part of my work is seeing people get hurt. I’ve watched too many of my friends suffer injuries, paralysis, and even lose their lives while chasing their dreams on the racetrack in cars and on motorcycles. But rather than letting these tragedies defeat me, they inspire me to create better products that can help prevent others from experiencing the same fate. I’m constantly experimenting with new materials, such as the prototype I showed you on our ride yesterday. Safety is paramount, and we need to keep searching for innovative solutions that can help us stay alive while continuing to pursue our passions. The risk will always be there, but we owe it to ourselves and our loved ones to do everything in our power to make these sports as safe as possible.

E-MOUNTAINBIKE:
Cycling Fashion is getting more and more subtle and straightforward. Where do you see TLD going?

TROY LEE:
My philosophy is that you need to strike a balance between both ends of the spectrum. That’s why I always tell my artists, “Go Mild, Go Wild!” We may sell more subtle black clothing with small logos, but there are times when going wild is necessary. When you’re on the racetrack, for example, it’s perfectly acceptable to wear bold colours and make a statement. During training, I prefer to keep things subtle, but on race day, I love to dress up in the wildest gear I can find. It’s fun!

E-MOUNTAINBIKE:
As the company grows, how did you/do you maintain integrity?

TROY LEE:
Racers give me integrity. Without the Racers, we would not be where we are today.

E-MOUNTAINBIKE:
Any Life Goals?

TROY LEE:
I haven’t done helmets for astronauts. So perhaps I still have a long way to go.

E-MOUNTAINBIKE:
What was your biggest mistake and what did you learn from it?

TROY LEE:
(takes a moment to answer) Honestly, I’ve never really thought about it. Mistakes happen, and I’ve certainly made my fair share – especially on the racetrack. There are moments where I wish I had made different choices, especially ones that resulted in injuries that left me in a wheelchair for six months.

Others have told me that bringing my family into the business is a mistake, but I disagree. My son Max is already in charge of the race team, and I’m integrating my daughter, sister, brother-in-law, and nephews into the company as well. It creates a cool vibe and a lot of trust. Plus, it’s important for me to teach them how to keep the business running in case something happens to me – it takes the pressure off me and gives me peace of mind.

E-MOUNTAINBIKE:
What are you grateful for?

TROY LEE:
My wife and kids for putting up with all my craziness.

E-MOUNTAINBIKE:
Weird question, but if your life were to end tomorrow morning, would you be at peace with your life?

TROY LEE:
For sure! I accomplished enough but I still have a lot more to give. I’ll keep swinging as hard as I can and give it my all.

E-MOUNTAINBIKE:
Creative blockage! What do you do?

TROY LEE:
I have the opposite problem, my mind is always racing with ideas and I jot them all down, but it’s difficult to find the time to bring them all to life. I’m not afraid of failure, so I’m willing to try anything. However, one challenge I face is that I have specific colours in my mind that are difficult to produce due to missing pigments. For instance, there’s no easy way to create fluorescent turquoise. Even something as simple as matching colours can be a struggle, as seen with this wall I’m sitting on that has a different shade of grey than the house wall. I’ve tried to paint it the same way, but it’s just not possible to match those colours perfectly.

E-MOUNTAINBIKE:
If you could do something completely different what would it be?

TROY LEE:
Gosh… it would be the worst thing in the world to do. I love racing and bikes too much. I am very happy where I am. But, if there’s one thing I do regret, besides not spending enough time with my family, it’s not putting more effort into learning new skills like playing an instrument or becoming fluent in multiple languages, but I barely speak English. Sometimes I daydream about being a carpenter and creating beautiful furniture from scratch. That’s something that really speaks to me, and I wish I had pursued it more.

E-MOUNTAINBIKE:
Besides family, what would you like to have more space in your life for?

TROY LEE:
I definitely want to see the world a bit more.

E-MOUNTAINBIKE:
If you could offer our readers one piece of advice, what would it be?

TROY LEE:
Chase your dreams and make sure you do what you love! … Ah and also give love to the people that give you the opportunity to move forward.

E-MOUNTAINBIKE:
Last but not least, do a fast sketch of my assistant Bonnie.

E-MOUNTAINBIKE:
I appreciate your time!

Der Beitrag A coffee with … Troy Lee. erschien zuerst auf E-MOUNTAINBIKE Magazine.

This year, too, there’s a clear trend towards light e-MTBs with a sportier orientation and smaller battery capacities. The main reason behind this trend is the newly-launched Bosch Performance Line SX motor, which delivers 55 Nm of torque and 600 W peak output, bringing considerably more power to the trail than the TQ HPR50 and FAZUA Ride 60 drives, for example. Despite being slightly lighter and more compact than Bosch’s Performance Line CX full-fat drive, the new SX motor is remarkably powerful, thus bridging the gap between light and full-power e-MTB motors. That said, many of the newly introduced e-mountainbikes featuring the brand-new Bosch SX drive, rely on little suspension travel and light components, which makes them suitable primarily for moderate trails and sporty riders. Furthermore, most of these bikes aren’t even available until the end of the year, while others are still in a prototype stage, meaning that they won’t be available for purchase until next year – what a pity!

Amongst the many exciting light e-MTB innovations there’s one product in particular that caused a massive stir: the new Pinion MGU drive system. In a nutshell, the German manufacturer combines an electric motor and gearbox in one package, forgoing two exposed, vulnerable components, the chain and rear derailleur. Churning out 85 Nm of torque, the Pinion MGU is aimed primarily at full-power e-bikes but, thanks to its wide range of applications and low maintenance requirements, is also a great match for urban bikes and e-SUVs that have to withstand the hardships of everyday riding scenarios. Moreover, the new motor/gearbox unit is also available as a speed variant for S-pedelecs, offering assistance at up to 45 km/h.

KTM Macina Scarp SX Exonic – As sharp as a sca(l)rpel?

With the KTM Macina SX range, the Austrians are expanding their eMTB portfolio, introducing the electric counterpart of their analogue XC racer. Built around a carbon frame, the KTM Macina SX Exonic is supposed to combine the best of two worlds, striking an optimal balance between weight and performance. Tipping the scales at 16.5 kg, the new KTM’s light eMTB comes equipped with a new Bosch Performance Line SX motor and 400 Wh battery, which can be removed from the top tube with an upwards motion. When embarking on epic backcountry expeditions, you can expand the battery with the 250 Wh PowerMore range extender, which can be secured directly to the battery cover. Unlike its analogue counterpart, which is available with either 100 mm or 120 mm of travel, the Macina Scarp SX Exonic generates 140 mm travel front and rear, which are supposed to make it suitable for rowdier trails with a scent of enduro. If you ask us, we can’t wait to take KTM’s new light eMTB to our home trails.

KTM Macina Mini ME SX – Mini-E for mini-me?!

KTM want your kids to have fun too, so the Austrain manufacturer is introducing the Mini ME SX, a kids-specific e-bike that forms part of the Macina SX portfolio. When developing the bike, the engineers’ focus was on creating a bike that offers excellent handling at the lowest system weight possible. The Mini ME SX rolls either on small 24” or 26 ” wheels and comes equipped with a new Bosch Performance Line SX motor, which draws its power from a 400 Wh CompactTube 400 battery. The new drive system allows for a new frame design and a compact, child-oriented geometry – even for e-bikes!

Find more information at ktm-bikes.at

BULLS VUCA EVO SPEED FSX 1 – Design and technology from the future

The new BULLS VUCA EVO SPEED-S pedelec Rolls into the future at the speed of light! It relies on a futuristic design language and comes equipped with the Speed-variant of the brand-new Pinion MGU E1.12 motor/gearbox unit. The 12-speed gearbox has 600% overall range and allows you to accelerate to 45 km/h without breaking a sweat. BULLS’ engineers will use the versatile frame platform as a template to create several more e-bikes, which will all form part of the VUCA model range, including a slightly different version of the VUCA EVO SPEED FSX 1 with mono-link swingarm, a step-through version and a 150 mm carbon trail bike. We can’t wait to test the BULLS EVO SPEED FSX 1 to tell you how it fares agianst its high-performance counterparts.

BULLS SONIC EVO AM SX 1 – slim tubing for a wide range of applications?

The BULLS SONIC EVO AM SX 1 features slim tubes and a discreet design language, which is also due to the slim 400 Wh battery that feeds the Bosch Performance Line SX motor. The super-thin seat stays merges seamlessly into the thin top tube. Despite its performance-oriented concept, the SONIC EVO AM SX 1 comes standard with a MonkeyLink mount under the stem and a rear light, which is neatly integrated into the chainstays, making BULLS’ lightweight, sporty trail bruiser suitable for late-night shenanigans. As soon as we get a chance to test BULLS’ slim trail eMTB, we’ll let you know how it performs.

Find more information at bulls.de

NICOLAI SATURN 14 SWIFT – Mechanical engineering meets Bosch SX motor

SX motor
The NICOLAI SATURN SWIFT isn’t a virtual training platform but a lightweight e-mountain bike made in Germany that prefers to hang out on real trails. The SATURN SWIFT generates 140 mm of travel front and rear and relies on NICOLAI’s distinctive, industrial design language with top-notch weld seams and countless CNC-machined parts. The Bosch Performance Line SX motor packs a punch – at least as long as the 400 Wh battery lasts – and is paired with a minimalist Purion 200 display/remote unit. We’re really looking forward to getting our hands on this bike for our first ride review – everyone else will have to wait until the end of 2023.

Find more information at nicolai-bicycles.com

ROTWILD R.X 1000 – Ab jetzt mit noch mehr Wyld

The new ROTWILD R.X 1000 relies on Pinion’s brand-new MGU motor/gearbox unit and huge battery with 960 Wh capacity, which was rounded up rather generously in the bike’s name suffix. The standard belt drive of Pinion’s 12-speed E1.12 motor/gearbox unit was replaced with a chain drive, while the big battery called for a wide downtube, which has a little bulge to remove the battery. Generating 170 mm of travel front and rear, ROTWILD’s beefy carbon eMTB should cut a good figure both uphill and on demanding descents. The ROTWILD R.X 1000 should be available from the fourth quarter of 2023.

Find more information at rotwild.com

CONWAY Ryvon LT 10.0 – No way, CONWAY!

CONWAY are one of the few manufacturers to pair a Bosch SX motor with a generous amount of travel, providing the new Ryvon LT 10.0 with 170 mm of travel front and rear. The 400 Wh battery is easy to remove and the magnetic charging-port cover can be attached to the top tube, preventing you from losing the cover in the process. According to CONWAY, the top-spec carbon variant of the Ryvon breaks under the 20 kg mark. If you’re looking for a light eMTB for your home trails you might want to take a closer look at the Ryvon’s short travel variant, the CONWAY Ryvon ST, which generates 150 mm of travel front and rear. Once we’ve tested the bikes, we’ll tell you which version suits which type of rider best.

Find more information at conway-bikes.de

THOK Projekt 4 – Printed Trail fun?

The Project 4 is THOK’s first light e-mountain bike. As the name suggests, it’s currently still a prototype, which is expected to hit the market in 2024. The special feature? Unlike most e-mountain bikes, the frame isn’t made of carbon but printed with aluminium using a specific 3D printing technique called SLM (Selective laser melting). The Project 4 combines 150/140 mm of travel but allows you to alter both the geometry and suspension travel. For the motor, THOK rely on the new Bosch Performance Line SX drive, which can be paired with different-size batteries with either 400 Wh, 500 Wh, 625 Wh or 750 Wh capacity depending on your needs and preferences. Moreover, the battery can be expanded with the optional 250 Wh PowerMore range extender.

Find more information at thokbikes.com

M1-Sporttechnik EN.400.SX – Enduro SX bike from a traditional German brand?

Just in time for EUROBIKE 2023, M1-Sporttechnik have integrated the new Bosch Performance Line SX motor into not one, but four different bikes, the EN, AM, CC and GT. These include three full-sussers with different amounts of travel and a fully-equipped commuter bike. We’re particularly intrigued by the EN variant, which combines 170/160 mm of travel and relies on a mullet setup with a smaller 27.5″ wheel at the rear and bigger 29″ Wheel at the front. The battery can be removed from the frame and the cover is secured with a Fidlock lock. The frame has several cut-outs around the rear shock and charging port and comes standard with a kickstand mount and cable connectors for a lighting system. For the production bike, the German manufacturer is planning to ditch the cable ports in favour of internal cable routing. We’re looking forward to testing the bike for our first ride review.

Find more information at m1-sporttechnik.de

Superior iXF 9.8 – New brand, new bike

With the iXF 9.8, Czech manufacturer Superior are rebranding their logo and at the same time venturing into the light e-MTB segment. For their 150/140 mm trail eMTB, Superior are pairing a 400W Bosch CompactTube 400 battery and Bosch Performance Line SX motor, which delivers 55 Nm of torque and 600 W peak power. The drive system is integrated into an elegantly-shaped carbon frame, which sports a rather discreet paint finish. DT Swiss supply the suspension, which is suitable for easier, more moderate trails.

Find more information at superiorbikes.com

Whyte Elyte 140

With the Whyte Elyte 140, the British brand has created an e-mountain bike with Bosch Performance Line SX motor that isn’t aimed exclusively at the elitarian crowds. Combining 140/135 mm of travel at the front and rear, the flagship model of the British e-downcountry bruiser tips the scales at just 16.9 kg, which makes it an interesting option for all eMTB weight-weenies. There’s enough room in the main frame triangle to accommodate both a water bottle and Bosch’s PowerMore range extender, which is included in the price with the top-spec model. The Elyte 140 should be available from December 2023. In our first ride review we’ll tell you how much truth there is in the manufacturer’s “Great British Bikes” slogan.

Find more information at whytebikes.com

Der Beitrag Eurobike 2023 – Eleven of the most exciting e-mountainbike products from Eurobike 2023 erschien zuerst auf E-MOUNTAINBIKE Magazine.

When Henry Ford founded the Ford Motor Company in 1903 and wrote automotive history with the successful Model T, just driving a car was an adventure in itself. Cars were special, exciting, and considered a big step towards a promising future. Almost 120 years later, Ford remain giants of the automotive industry, but times have changed: The roads are full of cars and driving them has turned into a largely mundane routine. Especially at Ford, where they’ve long focused on catering to the masses, apart from legends such as the Ford Mustang or the GT40. Like many automakers, however, Ford are currently undergoing a significant transformation. They’re discontinuing small cars like the Fiesta – probably because they can no longer compete with Chinese brands in this segment, like many other Western car companies – and reorienting themselves by targeting the adventure and outdoor segment. With the new motto “Adventurous Spirit”, this is where Ford want to position themselves and their passenger vehicles (these changes won’t affect their commercial division). Moreover, they believe that bikes and cars go hand in hand, and we’ve often experienced that this can in fact be the case. Whether in pursuit of maximum fun with a classic 911 and two high-end race bikes, on a 4,000 km road trip across Europe with the ID.BUZZ and our e-mountainbikes, or on off-road adventures with the new Land Rover Defender, to name just a few examples. But back to Freiburg, where we threw some bikes on the rear carrier of the Mustang Mach-E as well as the back of the Ranger Raptor and checked out what the two completely different vehicles are capable of – and whether they exude the same spirit despite all the technical differences!

What exactly is an adventure?

People have always been fascinated with adventures and heroic tales. Chances are you’ll have heard the Wild West stories of Davy Crockett, Buffalo Bill or Billy the Kid, but can we still experience a real adventure in today’s heavily regulated and highly developed environment, or is it a question of perspective? Everyone has a different idea of adventure, but most people think of it as an exciting and unpredictable event that takes them out of their comfort zone, leading to new experiences and memories. In this sense, adventures always have an element of the unknown and uncertainty because you don’t know what will happen. Adventures can happen on many levels. For example, there are adventures in the technical sense, such as the adrenaline rush induced by the incredible acceleration of an electric car, or the deafening roar of a monster truck.

What can we learn from ebikes?

Adventure is closely linked to freedom and independence. The things that cars were capable of before, when the terms traffic jam and rush hour traffic weren’t yet known, when the smell of gasoline was still considered sexy, and soot-covered faces and oily hands were thought of as manly. Cars have lost all of this during the last 100 years. Today, in the vast majority of cases, they’re just a means to an end, almost outcasts that protesters are trying to ban for good by supergluing themselves to roads. Bicycles are the new heroes of mobility, in the form of commuters and cargo bikes in the city, and mountain bikes in the outdoors, ideally with electric pedal assist. In Freiburg, it was the new STEVENS E-Inception FR 7.9.2 with the latest Bosch CX Race motor. However, let’s not forget that most riders take their bikes to trendy spots or parks by car. And the #vanlife trend is more popular than ever amongst bikers! So, one doesn’t exclude the other, and it ultimately comes down to having the right mobility mix. Once you’ve ridden an eMTB, you’ll be addicted to the feeling of being able to reach any destination while relying (almost) exclusively on your own strength, discovering new things behind every bend. And eMTB lets you live life to the fullest, connected with your surroundings, making you freer and letting you have more fun. Adventure is a feeling that starts in the mind. What has the automotive industry learned from this? Driving must be more than just getting from A to B. A car needs to make you feel free and independent again.

Wellness hotel vs self-catering at the Ford and STEVENS press camp

The Ford press camp gave us a taste of things that four- and two-wheeled off-road vehicles allow you to experience, and it was full of contrasts, from a wellness hotel and tightly scheduled test drives to self-sufficient camping in the outdoors with no schedule. The colourful bunch of bike and car journalists included a wide variety of skillsets, making the eMTB ride an adrenaline rush for some and just a warm-up for others. The same was true for the drive, though the other way around. But what matters, ultimately? That everyone got their fill of whatever puts a smile on their face. In this case, a shared enthusiasm about tech and machines, whether it’s feeling the power of the Mustang Mach-E with up to 500 electric ponies under the hood, experiencing the off-road capabilities of the huge Ford Ranger Raptor, or catching air aboard the STEVENS E-Inception. It’s not the kind of thing you experience every day, at least it isn’t for us. Okay, maybe except for the bike part. And at first glance, the cars and the bike couldn’t be more different. But they’re all exciting in their own way. Was it an adventure? Not in this setting. But did it make us yearn for adventure? Absolutely.

Times change

Must you always stay the way you are, and do you have to please everyone? Ford don’t seem to think so! The automobile company are targeting new groups, which results in heated debates, especially among die-hard fans. Most folks associate the Mustang with freedom, power, and the growl of a V8 engine. But Ford have reinterpreted it, introducing an electric model for the first time in Mustang’s 60-year success story. The SUV has little in common with the legendary icon, except for the lights and the mustang galloping on the grille. It’s on par in terms of performance, however, with an output of up to 487 hp. The new Ford Ranger Raptor is the polar opposite, making you feel like a ranger exploring the world’s most vast expanses. And you can just chuck your bike on the back, which is convenient and looks cool when you’re at the bike park. Our first impressions of the new Ford Ranger Raptor and Mustang Mach-E are promising, and they’re more than capable of real adventures, whether on- or off-road. We went looking for puddles that were big enough to prove it, but, unfortunately, we couldn’t find any at the press event. We’ve gone on many adventures with different cars in the past, and we always made a lot of special memories doing so. So, hopefully you’ll see us on another trip with the Ford Ranger Raptor or the Mustang Mach-E soon. Our visit to Freiburg let us taste blood, making us yearn for adventure the way we like it: charging up our e-bikes and heading off to countries we’ve never been to before, because adventure awaits in the unknown!

Conclusion

Over 100 years ago, any journey by car was an adventure, but the world has changed drastically since, and the role of the automobile needs to be redefined to keep up with the times. With the new Mustang Mach-E and the Ranger Raptor, Ford aim to put the fun and excitement back into driving. Can the car brand inspire the masses and keep the competition at bay with their new “Adventurous Spirit” motto? Only time will tell, but one thing is clear: An exciting new adventure has just begun!

Der Beitrag Is it all a matter of perspective? – Looking for adventure with the new Ford Ranger Raptor and Mustang Mach-E erschien zuerst auf E-MOUNTAINBIKE Magazine.

Why am I feeling anxious about where my life is? Am I giving enough to my relationships? Why is everyone else at the beach or out riding while I’m chained to my computer screen waiting for… well, for what? Are next week’s meetings sorted or am I stuck there sticking loose threads together by hand? Recognise that rising sense of pressure? Sometimes it stems from our own high expectations, other times from external forces, but either way, the impact it’s having on your wellbeing is probably a familiar feeling. It affects your sleep, seeing you toss and turn. On the rare chance you agree to meet mates, your heightened state of alert keeps you on edge. Herbals teas are a nice suggestion; so are books about being a better you, or conversations with wellbeing experts. But the best cure is to get outside and ride.

You’re probably well aware of how riding makes you fitter and stronger. But, you might cry, how can even the most mitochondria-rich cardiovascular system stand up against an ailing soul? Right now, the thought of being forced to spend time with oh-so-stoked riders might fill you with unease. Why would you want to go riding then? Easy. Riding is about more than the smug satisfaction of a low resting heart rate; it has the power to unleash an energy within your soul, break it up into smithereens and rebuild it from the ground up. Like LSD, without the need for a trip sitter. In the moment you’re waiting to drop into the trail, you’ll notice a shift – an abating sense of oppression. Just watch it wane, as your sense of strength comes back to the fore.

Step outside of your head and into your body

How often do images of your bank balance flash into your head as you pick a line through a rock garden? Do Excel spreadsheets or schedules blur your vision? Rarely, right! Riding is the most fast-acting antidepressant we’ve ever come across. Line choice and landings are so all-consuming that your mind has no choice but to be in the moment. Two hours later, you’ll swing into your driveway and realise that you haven’t once dwelt on the thoughts that had been pre-occupying you so much.

The importance of a reset like this is on par with the need for open windows in a stuffy classroom full of teenage boys after a PE lesson. And while going for a ride is only a temporary measure against intrusive thoughts, we can safely say that there’s no risk of immunity – it works ride after ride. New perspectives will always be out there; you just need to go and grab them. A brief respite and some gasps of fresh air will be enough to bring you back out on top and pivot you into a more positive headspace. Switch your phone into focus mode and get outdoors. Disruptive thoughts can float on by; you’ve got better things to do. Focus on your lines, let the bike do the rest.

Fear > Fear

Some cry, why take on the added challenge of mountain biking when your work, love, life and other four-letter words are stressful enough? Isn’t there a contradiction in there somewhere? Hell, no. The flood of hormones that are released while shredding are admittedly the very same stress hormones, but in this situation they’re acting differently. That stupid grin on your face after taking a corner too tight or nailing a steep, loose climb? That’s a rewarding rush of adrenaline. There’s a reward from taking on and subsequently coming out of each challenge. Let it be a reminder that yes, you can do it. It’s manageable – you are managing it. Take that thought and allow it to lend you some swagger when you get off the saddle. It’s a little-known phenomenon that we’ve dubbed ‘the bike effect’ and it translates across everything in life. If you’ve bossed that trail, then there’s nothing stopping you from bossing the rest of your life. Like a snowball, riding is a magical toy that lets us alter our perception, discover exactly what you’re capable of and turn stress into stoke.

Mental health is a hugely complex topic, but we’re surprised more people don’t prescribe riding as part of the toolkit. For an immediate sense of relief from negative thoughts, hitting the trails reminds you that you’re capable – and that’s a comforting thought that we’ll be deploying from now on as armour against sinking thoughts and stress.

Der Beitrag Shaking off your demons – What does riding have to do with wellbeing? erschien zuerst auf E-MOUNTAINBIKE Magazine.

Ever since its foundation, the brand from Andorra and the legendary story of the company’s origins involving a Belarusian investor have been surrounded by mystique. A lot was announced, but for a long time no products were available. Malicious tongues claim that Forestal do not even exist. We had the opportunity to test the Siryon light eMTB in our big comparison test and were quite impressed – however, we still wanted to find out who and what is really behind it.

In a small country before our time…

In the middle of the Pyrenees lies the Principality of Andorra. The small country in the midst of mountains between Spain and France is known above all for its many kilometres of ski slopes. It is one of the smallest countries in Europe and barely larger than the capital Andorra La Vella, where the HQ of Forestal is based. Due to the limited space available, the houses here grow upwards rather than outwards. Finding the Forestal company building is like looking for a needle in a haystack, and Forestal make use of what is already there: An old car dealership serves as their development and production site with the faded logo of a major car manufacturer still emblazoned on the wall. It’s all quite inconspicuous, only a small showroom and a black garage door with the company logo reveal what is going on behind the thick concrete walls. We paid a visit to Forestal to shed some light on the mystery.

What do supercars and helicopters that turn into drones have to do with eMTBs?

The black gate conceals parking spaces inside the building because space for parking is as scarce in the city as building space. Forestal’s company building is built like a multi-storey car park, with access ramps leading from floor to floor. There are a total of six floors, which can also be reached via a lift and stairs – it’s quite easy to get lost, to be honest! Luckily, we have Saša to pick us up and guide us through the cool and somewhat sterile-looking rooms. On the very first floor, a surprise already awaits us: Next to eMTBs, we encounter helicopters. Before we even start to talk about Forestal, we cannot stop ourselves from asking what on earth do helicopters have to do with the development of ebikes? The simple and matter-of-fact answer is that the owner is planning to offer taxi flights with converted helicopter drones for special guests and is therefore tinkering with helicopters in the Forestal company building. Exciting, but the small helicopters do not really inspire confidence and it’s quickly becoming obvious that Forestal are different. Earlier that morning we went for a quick visit with old friends from COMMENCAL, who are also based in Andorra – but the differences couldn’t be more evident. While COMMENCAL have grown from the core of the scene over decades, Forestal were built with a lot of money in a very short time. You can feel and see this immediately in the way that employees in these companies interact with each other, in the company buildings, and in the respective company cultures – which is not really tangible yet at Forestal – but also in the conception of the products.

We don’t get to meet the Belarusian tech millionaire, but according to the Forestal team, he rides bikes himself and is said to have made his money in the IT and gaming industries. He is not involved in day-to-day operations and prefers to stay in the background as investor and inspirational input.

In the former car dealership, the production winds whimsically upwards via dark ramps. In the vertically-structured company, a different work step takes place on each floor: from R&D downstairs to assembly and shipping on the 3rd floor. No matter on which level the ramp spits us out, we are surrounded by cool concrete walls bathed in artificial light. Depending on the floor, the flair and interaction of the staff varies from open and friendly to duty-oriented and isolated. There seems to be little interaction between the floors. We have an impression that a stronger corporate culture and places for exchange and meeting across all floors would do Forestal a lot of good. The best example is the spartan kitchen on the lowest floor, which fulfils basic nutritional needs, but doesn’t necessarily promote social gathering.

From the beginning – The development process at Forestal

The entire development of Forestal takes place in-house: of the 55 employees, 15 people are responsible for the development process. When it comes to design, the Forestal founder likes to have his say and set challenges for the designers. Brand sneakers, concept cars, even aeroplanes – the design of a wide variety of products that the owner likes must find their way into the colours and shapes of the bikes. The Forestal bikes look really cool and stylish – so somehow this process works, chapeau!

The design process is followed by building a prototype. The bikes are first made of steel and after conducting a few tests transferred to the carbon mould. At first glance, the rather rustic steel frame is reminiscent of Frankenstein’s bike, but thanks to various adjustment options, it combines frame sizes M and L in one bike. Different headset cups also allow for different head tube angles. The test laboratory contains numerous pieces of equipment for testing materials, and this is where the endurance tests of the frames as well as the tensile and compression tests are done. While you see this kind of equipment at some bike brands, everything that followed in the next few rooms is extremely rare in the bike industry. Forestal do most of the development of the drive system itself. They have taken on the mammoth task of developing their own complete concept right from the start instead of just buying an already existing motor system and integrating it into the frame with a few adjustments. Respect! Though, it is obvious that the risk and effort are amplified. Another challenge was that much of the development time coincided with the pandemic, and trips to Asia or face-to-face meetings were not possible, or very limited. The idea of going straight for a light eMTB was also quite progressive at the time.

BAFANG build the motors on commission exactly to Forestal’s specification and were the only motor manufacturer who were interested and had sufficient production capacity for the young and at that time still unknown bike company. After all, there is still a difference if a well-funded start-up like Forestal or an established billion-dollar company like Specialized come knocking on a motor manufacturer’s door and want a custom production. Forestal then built the frame around the motor, which boasts a low total weight of 1.9 kg thanks to the titanium parts and magnesium housing.

The depth of the development is impressive. Not only are the motor and battery system developed in-house, but so is the rest of the electronics found on the bike, such as the colour display, GPS device and circuit board, including both software and firmware. The prototypes of the circuit boards for the large touch-sensitive display, which runs on Android, are soldered on site before they go into production. Thanks to the integrated eSIM card, the display fitted into the top tube comes with an extensive range of functions such as navigation, training and riding modes as well as anti-theft protection. In the future, a lithium polymer battery will also be integrated in the head unit so that the bike, in the event of theft, can be located even if the main battery is disconnected. A simpler version without connectivity and without a display will also be launched on the market in the future.

Production Privée – A factory within a factory

Two floors above the development department are the manufacturers of Production Privée, dedicated to the development and production of bikes and components with cutting-edge manufacturing methods. The Andorian bike manufacturer were bought by Forestal in 2020, including its employees and founder, and the two companies now work closely together.

Among other things, the Production Privée team is conducting research into thermoplastic frame construction. The material they’re using is called Peek, which is mainly found in the aerospace industry. The dry laminate is cut and positioned by a robot and then hardened with resin. The frames are not made from a single piece, but from two halves, which are then glued together. The first prototypes were developed and produced in collaboration with the University of Aachen and a manufacturer of sports car carbon rims, but the goal is to produce their own carbon frames in Andorra. The advantage of thermoplastic composite technology is that the manufacturing process allows for 90% of the process to be automated, meaning that theoretically 8,000 frames could be produced with only eight employees. In addition, thermoplastics are more recyclable than classic carbon frames, which once produced cannot be easily recycled and are therefore virtually special waste. Thermoplastic carbon frames, on the other hand, can be simply remelted or reshaped under heat.

In addition to research on the thermoplastic method, Production Privée also produce frames made of steel and titanium, so a giant welding robot that can weld steel frames automatically occupies their hall. This process allows for consistent high quality, clean seams and enables three frames to be welded in 12 minutes. The CMT (Cold Metal Transfer) welding technique is designed to eliminate the need to treat the welded frames again. One of the Production Privée bikes goes by the name of Shan No. 5, and in its third iteration combines a steel main frame with a carbon rear triangle. Compared to a steel rear triangle, the weight is almost halved from 1.6 kg to 850 g and the finished bike with robust DH tires is claimed to weigh just 15 kg. They are also experimenting with steel and alloy frames by bonding them together. Here you can clearly see the great interest in research and experimental use of new and innovative production methods and materials.

It’s getting colourful – Paintwork and assembly in-house

Colour plays a major role, which is why the paintwork at Forestal was inspired by various light phenomena and is named Halo, Neon or Diode, for example. In their configurator, you can choose from many options or put together your own custom paint job. For example, you have the option of the bike being custom painted in the colour of your car. The paint shop occupies an entire floor in the Forestal facility and was relocated from Taiwan to Andorra during Covid. They set it all up there and due to the pandemic, all the painters had to be trained without the supplier’s help. Preparing the frame for the paintwork alone takes a lot of time and effort, as it has to be sanded for 1.5 hours before the painting process can be started.

The frame is then primed and sanded again for another 1.5 hours before up to six final coats of paint are applied. As with hypercars, the paintwork is polished and checked by hand at the end. Every day, up to ten frames leave the paint shop mostly with a customised paint finish.

The bikes are then assembled on the floor above. The matching components of the respective bike are prepared beforehand in the warehouse and come ready for assembly. So all the parts, such as the steering tube or the chain, already have the right length, making installation quicker and easier. Assembling a bike takes around four hours and, as with AMG motor construction, one mechanic is responsible for an entire bike. We looked, but we couldn’t find a plate with the builder’s signature though ;).

Checking out Marc Busquets’ Forestal Cyon bikes

As a treat, we had a closer look at the private bike of lead developer Marc Busquets. He has built it with high-end parts and unique details and thus made his (and many a rider’s) dream come true.

Conclusion

The depths to which Forestal have gone in terms of development are impressive, and on top of that they’re researching innovative manufacturing methods and projects together with Production Privée. Much of the work, such as development, painting and assembly, is done at the HQ in Andorra and is undeniably exceptional. Despite some ambiguity about the background of the company and the lack of a vibrant corporate culture, we salute the team in Andorra for what they have achieved in just a few years, creating something quite extraordinary!

more infos: forestal.com

Der Beitrag Factory visit: Forestal Bikes in Andorra – From underdog to innovation leader? erschien zuerst auf E-MOUNTAINBIKE Magazine.