Case Study: Karbon Kinetics achieves rapid development of the world’s lightest electric two-wheeler with Protolabs injection moulding

Karbon Kinetics Ltd - Customer Case Study

Karbon Kinetics Ltd (KKL), a British company, faced the challenge of developing the Gocycle, the world's lightest production electric bicycle. They needed to manufacture high-specification, durable, and aesthetically pleasing mechanical components from a difficult-to-mould material—a specially formulated nylon filled with 60% long glass-fibres. To overcome these manufacturing hurdles and compete with larger manufacturers, they turned to Protolabs for its rapid injection moulding services and expertise.

Protolabs worked closely with KKL to analyze the CAD models and used its proprietary Protoview software to simulate the injection moulding process. They optimized gate locations and determined the precise pressure, temperature, and injection velocity needed to successfully mould the high glass-content material, eliminating warping and achieving a perfect surface finish. As a result, Protolabs developed 47 individual injection-moulding tools, enabling KKL to rapidly obtain high-quality parts. This solution provided KKL with a fast, responsive, and cost-effective manufacturing process that allowed them to successfully bring their innovative and stylish electric bicycle to a competitive market.

Karbon Kinetics Ltd

Richard Thorpe

Designer and Founder