Nicolai Bikes (Germany) - NICOLAI has completely revised the chassis for the 2022 EBOXX. For the elaborate frame construction, the manufacturer traditionally uses 7020-T6 aluminum, which has an approximately 30% higher tensile strength and an approximately 20% higher elastic limit compared to the 6061-T6 alloy commonly used in bicycle construction. The argument of sustainability in terms of recycling and the goal of a complete circular economy are also important arguments for the manufacturer. Production of the NICOLAI EBOXX series takes place entirely in the company’s own factory at its German site in Mehle, Lower Saxony.

A brand new feature for the EBOXX is a completely CNC-milled head tube, in which the internal cable ports are integrated. Compared to the turned and butted head tube of the previous model benefits significant weight savings and gains in stiffness and aesthetics. The down tube, an extruded multi-chamber profile with the battery opening underneath, has also received a redesign to accommodate the larger 750Wh battery. The previous extrusion is also updated with a lighter design. The rear end has also been redesigned: the ‘Hollow-Milled’ component is now used as the compression strut yoke, again combining weight savings with stiffness gains.

Hollow-Mill is a technology NICOLAI uses in the construction of highly stressed, complex and voluminous components to achieve maximum durability with minimum weight. Hollow-Milled parts are manufactured by NICOLAI on state-of-the-art 5-axis CNC machines and are hollow milled from the inside. During design, NICOLAI uses FEM software (Finite Element Method) to simulate the loads occurring in real-world use to optimize the shape (topology) of these components. Topology optimization makes critical stress areas of the design visible. These can be strengthened by adding material, while unnecessary material can be saved in low stress areas.

These redesigns of the 2022 EBOXX frame have resulted in a weight saving of over 500g compared with the previous model. This effectively compensates for the additional weight of the larger 750Wh BOSCH Smart System battery. When using the 625Wh battery on the EBOXX models with a 4th generation BOSCH Performance Line CX drive combined with the electronic ROHLOFF E14 shifting system, the total bike weight can be reduced by half a kilo.

The new frame has clearance for 203mm brake discs. NICOLAI has revised the rear for this purpose and designed new sliding dropouts for tensioning the Carbon Drive belt, whose integrated brake mount has been reinforced with a torque support to compensate for higher braking forces.

NICOLAI points out the outstanding durability and extreme load capacity of its EBOXX models by granting a 5-year warranty against material failure: frame breakage even for competitive use, under the toughest riding conditions and with a total weight limit of 130kg. NICOLAI further backs its frame up to 150kg, however, the suppliers of most components do not follow suit.