This commercial-grade lightweight folding bike is engineered for urban mobility distributors, fleet operators, and bicycle brands. Built around a hydroformed 6061-T6 aluminum frame, the design balances structural rigidity with a dry weight starting at 9.8 kg. The proprietary dual-locking hinge mechanism prevents lateral play after prolonged mechanical cycling. Designed for bulk commercial deployment, retail distribution, and micro-mobility sharing programs, this platform supports full custom branding, color matching, and component specification adjustments to match regional market requirements.
Key Product Features
Zero-Play Dual-Stage Hinge: CNC-machined aluminum latch with a secondary safety pin prevents accidental folding under load and eliminates frame flex.
Optimized Weight-to-Load Ratio: Weighs 9.8 kg while maintaining an ISO 4210-2 structural load rating of 110 kg.
Compact Folded Envelope: Reduces to 780 x 320 x 620 mm in under 10 seconds without tools, fitting standard multi-modal transit compartments.
Integrated Cable Routing: Internal routing protects brake and shift lines from environmental wear and snagging during folding cycles.
Modular Drivetrain Interface: Standardized BSA threaded bottom bracket shell and ISO disc brake mounts allow straightforward component localization.
Technical Specifications
|
Parameter |
Specification |
|
Frame Material |
Hydroformed 6061-T6 Aluminum Alloy |
|
Fork |
Rigid 6061 Aluminum, 1-1/8" Threadless |
|
Net Weight |
9.8 kg (excluding pedals) |
|
Max Payload Capacity |
110 kg |
|
Folded Dimensions |
780 x 320 x 620 mm |
|
Wheel Size |
20 inches (406 ISO) |
|
Drivetrain |
Shimano Altus 8-Speed / Optional Gates Carbon Drive CDX |
|
Brake System |
Mechanical Disc Brakes (160 mm rotors) / Optional Hydraulic |
|
Seatpost |
33.9 mm x 550 mm Al-Alloy with laser-etched insertion limit |
|
Surface Finish |
Powder Coated / Anodized with clear anti-UV protective coat |
Frame & Structural Design
The frame utilizes hydroformed 6061 aluminum tubing to optimize wall thickness across high-stress zones while shedding unnecessary mass.
TIG Welding: Robotic TIG welding ensures penetration depth consistency and uniform bead profiles across all primary joints (head tube, bottom bracket, and main spar).
Main Hinge Assembly: The folding hinge is forged from a single aluminum block, eliminating casting micro-voids. The pivot pin is precision-ground stainless steel running on sealed bronze bushings to resist salt spray and grit ingress.
Fatigue Testing: Frames undergo 150,000 vertical drop cycles and 100,000 pedal load cycles per ISO 4210 test standards prior to production sign-off.
Components & Configuration
Supply configurations can be tailored to target retail price points or commercial durability specs:
Cockpit:
Telescopic alloy handlebar stem adjustable for rider heights between 145 cm and 190 cm; dual-density kraton rubber ergonomic grips.
Wheelset:
Double-wall aluminum rims (24H front, 28H rear) laced with 14G stainless steel spokes to CNC-machined sealed-bearing hubs.
Tires:
20" x 1.5" urban commuter tires with 3mm puncture-resistant aramid belts and reflective sidewall strips.
Saddle:
Vacuum-formed waterproof PU leather top over high-density foam padding on a steel rail chassis.
Applications
Urban Micro-Mobility Fleets: High-cycle durability for station-based or dockless rental networks requiring minimal daily maintenance.
Corporate Commuter Programs: Compact storage solution for office buildings, employee incentive programs, and last-mile transit integration.
RV, Marine, and Outdoor Retail: Portable transit option for camping, boating, and automotive trunk storage distributed through sporting goods channels.
Municipal Transit Integration: Deployed by transit authorities for employee field transit and inter-station transfer.
Customization Options
Color & Branding: Custom Pantone color powder coating, laser-engraved headtube badges, and water-transfer or vinyl-cut frame graphics.
Component Tiering: Swap between Shimano mechanical groupsets, internal gear hubs (Shimano Nexus 3/7/8), or belt-drive configurations.
Accessory Bundling: Pre-installation options for integrated LED front/rear lights (dynamo or battery-powered), rear cargo racks, mudguards, and kickstands.
Packaging Customization: Retail-ready individual carton printing with client barcodes, manuals, and multilingual labeling.
OEM & ODM Manufacturing
3D CAD modeling, FEA (Finite Element Analysis) stress simulation, and CNC-machined functional prototype delivery within 14 business days.
In-house mold design and aluminum extrusion die management, ensuring proprietary frame geometry exclusivity for brand partners.
Laser-etched unique serial numbers on every frame down-tube linked to material batch certificates and production timestamps.
Quality Control
Incoming Raw Material Inspection: Spectrometer testing of raw aluminum billets to verify 6061 alloy chemical composition.
Dimensional Verification: CMM (Coordinate Measuring Machine) checks on welded frame jigs to maintain alignment tolerance within +/- 0.5 mm.
Coating Adhesion Testing: Cross-hatch adhesion testing and salt spray corrosion testing (ASTM B117) exceeding 500 hours on painted surfaces.
Final Assembly QA: 100% inline torque verification for all critical fasteners (handlebar clamps, hinge bolts, axle nuts) and brake/shift calibration bench tests.
Packaging & Shipping
Carton Specification: 5-layer double-wall corrugated export cartons with molded EPE foam inserts locking the front and rear wheels to prevent transit shock.
Assembly State: 95% pre-assembled; final setup requires only unfolding the frame, securing the handlebar stem, and attaching pedals.
Container Loading Optimization:
• 20ft GP Container: Approx. 180 units (boxed)
• 40ft HQ Container: Approx. 420 units (boxed)
MOQ & Lead Time
Minimum Order Quantity (MOQ):
• Standard configuration / Stock color: 50 units per SKU.
• Custom OEM color / Brand graphics: 200 units per SKU.
Production Lead Time:
• Sample orders: 15-20 days.
• Bulk production: 35-45 days following deposit receipt and artwork approval.
FAQ
Q: What are the exact structural load certifications for this folding frame?
A: The frame and fork are tested in accordance with ISO 4210-2 standards, rated for a maximum total rider and cargo load of 110 kg. Test reports covering frame fatigue, fork impact, and handlebar stem security are available upon request for compliance filing.
Q: Can we specify our own components, such as brakes or gear systems?
A: Yes. As an OEM/ODM manufacturer, we can substitute drivetrains, braking systems, and touchpoints (saddles, grips, tires) to meet your target bill of materials (BOM) and regional market standards.
Q: How do you prevent loosening or wear in the folding hinge over extended use?
A: The primary folding joint uses an adjustable eccentric bolt paired with a dual-stage locking lever. This mechanical setup allows operators or end-users to compensate for micro-wear over years of cycling, maintaining a rigid, play-free connection without specialized tools.
Q: What is your standard procedure for defect claims or warranty support?
A: We maintain a 2-year structural warranty on frames and a 1-year warranty on mechanical components against manufacturing defects. Replacement parts are dispatched via air courier within 3 business days upon receipt of photographic or video evidence and corresponding frame serial numbers.
Q: Are the bikes shipped fully assembled or do they require retail shop setup?
A: Units are shipped 95% pre-assembled in reinforced export cartons. End-users or retail mechanics can complete final setup-securing the handlebar stem, tightening pedals, and adjusting tire pressure-in under 15 minutes.
Q: What export documentation and compliance tests do you provide with bulk shipments?
A: Each shipment includes commercial invoices, packing lists, Bill of Lading, Certificate of Origin (Form E, CO, etc., upon request), material test reports (MTR), and ISO 4210 test summary sheets for customs clearance and regulatory compliance.
Request a Quote
To receive a detailed quotation including tiered volume pricing, freight estimates to your destination port, and sample order procedures, submit your project specifications directly to our engineering sales team:
Email: sandy@gentlesports.cn
Direct Inquiry Form: Specify your target volume, required customizations, and destination port for a response within 12 business hours.
Hot Tags: lightweight folding bike, China lightweight folding bike manufacturers, suppliers, factory
