vanRaam gives comprehensive overview of its in-house production
Comments Off on vanRaam gives comprehensive overview of its in-house productionSource: Bike Europe Image sources: vanRaam, Bike Europe
The LEVA-EU member gives exclusive insight into how it produces its high-quality, customised bikes as it strives to make cycling more accessible for disabled and senior riders.
The Dutch brand’s bicycle factory in Varsseveld is a 13,500 m² facility which facilitates processes including in-house frame production, robotic welding, 3D laser cutting, CNC machining, and wheel production.
“We have the biggest factory in the world for making tricycles,” said vanRaam’s CEO Jan-Willem Boezel, who, after steering the company’s technical developments for nearly 30 years, took on the position of CEO in January 2025.
vanRaam’s company ethos of increasing cycling accessibility
Its product range of trikes, tandem bicycles and rehabilitation bikes is targeted at seniors and those who are less able to use a regular bicycle. Translated into English, the company’s slogan is “We just make it/We make it normal,” referring to making bikes accessible to everyone regardless of age or physical ability, and that if a cycling option doesn’t yet exist for a rider, it will make it possible.
Configure to order
The company adopts a “Configure to Order” (CTO) strategy to deliver bespoke, individualised manufacturing.
Most of its frame production is standardised, with the exception being bikes for physically disabled riders who need custom-made adjustments according to their requirements, for example, all handling equipment configured on one side for one-armed use.
In a dedicated area of the factory the steel frames are created. Firstly, steel parts are laser-cut before being welded by vanRaam’s robotic welding machines. The process is followed by key parts being manually clamped together.
Then the bike customisation takes place according to customer requirements in terms of colours and accessories.
Machinery capabilities and production capabilities expansion
For its adaptive bicycle frames, steel pipes are cut, shaped and drilled by an advanced, automated Trumpf machine, which automates complex tube production for models such as the Easy Rider, Maxi, and Fun2Go. The machine reduces manual labour and increases efficiency by 60%.
To support its parts production further, vanRaam acquired companies, such as Your CNC Solutions, to use automated turning and milling machines to support internal production and external customers. It also uses several 3D printers for creating steel and plastic parts, as well as prototyping with custom components.
High efficiency and quality control for bicycle completion
Not only do vanRaam robots automate efficient production processes, but they also each check the work of other robots, such as a quality control check of frame tolerance from each batch, before they enter the in-house paint shop. The company’s new colour, material and finish process requires every frame to pass through the powder coating paint line three times.
After the wheels, steering and suspension have been assembled, the models are separated with six to eight stations per line with a 30 minute takt time. For bikes requiring customised assembly, a single mechanic will work on completion.
vanRaam’s electric system development
As 99% of its products are now electric, it has a team of 10 people working on its in-house developed motor system, and developing its software. As part of its proprietary electric pedal support system, its team has also developed the Silent System as a reverse pedalling solution to help less-able riders.
With regard to its batteries, vanRaam uses European suppliers (BMZ and Cleantron), with the brand developing its own battery management system (BMS) in-house.
With technical developments, vanRaam always keeps its users in mind, with Boezel noting that keyless entry, sensory-friendly and low-stimulation apps are important in elevating bikes to be practical mobility tools for users.
Model development time
vanRaam’s in-house capabilities enable lead times between 3 and 6 weeks. In terms of total time for developing a model, Boezel confirms the minimum amount is a year, stating that prototype production, testing and remodelling parts can be done in-house, without having to wait for suppliers. He states that it only relies on Asia for a few components, like hubs.
Polish production facility for meeting increasing demand
As well as the 13,500 m² production facility in the Netherlands, the company also has a second 6,000 m² site in Poland, accounting for 60% of its production capacity to meet growing demand with the production of existing models.
“The difference with Poland is that this only has series production, and in large quantities. For example, our Easy Rider model. For new models like Thuja, we prefer to keep those competencies in the Netherlands as production stabilises.” says Boezel.
To facilitate its mass-production further, vanRaam is doubling the size of its Polish production facilities, by building a new factory of 6,000 m² that’s expected to open late 2026.
Solid foundation for international growth
vanRaam is in the top 40 list of all Dutch manufacturers, reporting a net turnover of €76 million in 2024. And with over 20% of the EU’s population being 65 or older, vanRaam has substantial potential for this target market.
The company currently has an annual capacity of 18,000 units, and has the potential to quadruple, with its growth and scale having been supported by German investment company Armira since 2023.
“Armira is the largest shareholder in the company, but supports us from a distance. They only invest in profitable businesses, and we can leverage their experience in internationalisation.” says Boezel.
For distribution, vanRaam has a dealer network of 300 in its main market, the Netherlands, and 200 in its second largest in Germany, with other key regions being Belgium and Scandinavia.
The company has confirmed that in terms of sales channels, the revalidation market accounts for 25% of sales, with 75% being from bicycle dealer networks.
The success of vanRaam’s unique offering
Its successful focus on inclusivity, accessibility and sustainability is evident, with the company achieving 15% annual growth in market conditions which many others bicycle brands have found difficult. “We’ve always tried to follow our own path and not look too much towards what the rest are doing. We are the market leader, and we want to stay that way,” concludes Boezel.
