Copyright Interesting Engineering
Students in Germany have built ultra-light cargo bikes from recycled aircraft parts to help and support the flood-stricken communities in Spain’s Valencia region. For the project, the group of students from the Department of Sports Equipment and Technology at Chemnitz University of Technology (TU Chemnitz) joined forces with UK bicycle brand Vielo to craft four ultra-light cargo bikes. The bikes were made from old Airbus aircraft components and engineered for purpose-driven mobility. They were later shipped to Valencia to assist residents affected by the 2024 floods, which claimed at least 224 lives across the province. “For our Sports Engineering students, this project was a unique opportunity to combine sustainable materials use, lightweight construction and social engagement,” Jens Buder, a research associate at department, revealed. Recycling with a purpose The students made the bikes’ frames from two-inch (55-millimeter) carbon-fiber tubes that once served as structural components in Airbus A380. The recycled materials were supplied by Elbe Flugzeugwerke GmbH (EFW), a Dresden-based aircraft maintenance company. Weighing just 28 lbs (13 kilograms), each bike can carry loads of over 154 lbs (70 kilograms). The four prototypes were delivered to two of the hardest-hit towns in Valencia to help restore mobility in the aftermath of the floods, in October 2025. According to Buder, who also works as an engineer at Vielo, the aircraft-grade carbon tubes were first cleaned and cut to size, then bonded using an epoxy-carbon composite. To ensure long-term stability, the students reinforced the joints with multiple carbon-fiber layers. The final result was a frame with a high strength-to-weight ratio comparable to professional-grade bicycles. “From CAD design to jig construction and carbon winding techniques, they implemented the entire prototype process hands-on,” Buder emphasized. However, the process of building the bikes came with its fair share of challenges, as the students had to troubleshoot several manufacturing issues. These included discoloration of the carbon after oven curing. The team resolved it by applying an epoxy topcoat, which both protected the surface and gave the frames a uniform glossy finish. “At first it was a real challenge, however after building the first bike, the process went surprisingly smoothly,” Louis Ladewig, one of the students involved in the project, said. Sustainability in motion The humanitarian side of the initiative was coordinated by Valencian Vielo athlete Juan Dual, known for leading volunteer cycling efforts in disaster-affected areas. Following the floods, Dual organized a team of more than 100 riders to deliver aid to remote locations. Vielo co-founder Trevor Hughes personally collected the bikes from TU Chemnitz and embarked on a 1,615-mile (2,600-kilometer) journey to deliver them to Valencia. He documented the trip as part of the firm’s ongoing Vielo Road Diary series. As per Stephan Odenwald, PhD, head of the Department of Sports Equipment and Technology, the collaboration demonstrated how circular economy principles can be applied in engineering education. “The direct connection with Elbe Flugzeugwerke GmbH was key to repurposing certified aerospace carbon structures,” he concluded in a press release. “I am especially proud that our students turned this idea into working prototypes.” The project was supported by Goodyear/Cambrian Tyres, Token, Satori, WTB, Tektro/TRP, and Ineos Automotive. It shows how modern engineering can blend sustainability, collaboration and social purpose to help rebuild communities in need.
