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Introducing Trek's low-impact aluminum

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When we conducted our first full emissions audit in 2021, we learned that aluminum was the single biggest contributor to our overall greenhouse gas emissions. So we’ve tackled this problem-material head-on, rethinking everything about how and where we source aluminum. The key? It’s not just the material but how it’s made.

We’re now sourcing aluminum from suppliers powered by renewable energy and even helping our partners upgrade their facilities to meet the higher environmental standards of our new sourcing policy.

This shift is already making an impact. As of February 2025, thousands of Trek city, mountain, and road frames have been made with low-impact aluminum — and we’re just getting started.

Here’s a closer look at our journey in pursuit of the world’s lowest-impact aluminum bike.

Same bikes. Made better.

Our path to low-emissions aluminum

Emissions audit

In 2021, we learned aluminum was the top contributor to our overall emissions. Much of the aluminum we were using was made at facilities powered by fossil fuels, which is common in the the bike industry and beyond. But when that same aluminum is made using renewable energy, the overall impact decreases significantly.

Supplier outreach program

So, we launched a massive supplier outreach effort. We dug in and asked questions that hadn't been asked before and learned a lot along the way. This work has given us a clearer picture of our supply chain, good and bad.

Developed training

We teamed up with the Dutch nonprofit Shift Cycling Culture, the German development agency GIZ, and other bike brands to develop training on the core concepts of sustainability, carbon accounting, regulatory guidance, and data analysis to help our suppliers identify the biggest impact areas in our operations.

All-new sourcing policy

At the same time, we created an all-new aluminum sourcing policy that ensures our partners in the supply chain are as dedicated as we are to lowering emissions. The policy gives us better transparency into our Scope 3 emissions and outlines clear requirements regarding the acceptable emission levels of our products.

First low-impact aluminum bike

Today, the first low-impact aluminum Trek bicycle frames are already available at Trek retailers. All of this is great for Trek — but we're thinking bigger. We're banking on this meaning massive changes for the industry.

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Our most popular aluminum bike, by the numbers

Changes in emissions (kg CO2e) as per component on Gen 3 Marlin 5. An estimated reduction of 53.7% in CO2 emissions will be achieved after switching the components listed to low-carbon aluminum. Transition to low-carbon aluminum for parts is in process and in various stages of completion.

Before

Our analysis of Marlin helped pinpoint the bike’s highest-impact parts so we could focus our efforts on reducing emissions where it matters most.   

Fork

Marlin's fork contains a large amount of aluminum, steel, and magnesium, offering plenty of room for improvement. However, after researching our supply chain, we discovered these forks are using post-consumer recycled materials in the castings, which places the emissions well within the suitable range. 

Frame

Through supplier outreach, we learned our aluminum frames were being produced using carbon-intensive fossil fuels – likely coal power. Since then, we’ve worked with multiple factories to implement a hydroelectric process that helps massively reduce frame emissions. 

Rims, handlebar, seatpost and stem

We are in the process of implementing low carbon aluminum in our rims, with plans to make changes to other parts as well. 

Why is this in percentages?

We estimate product emissions by modeling production processes, materials, and energy use. As we learn more, we refine our models for better accuracy. Since our 2021 report, we’ve updated Marlin's analysis four times. Showing reductions as percentages gives a clearer picture than using absolute numbers.

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What’s next for low-impact aluminum?

In the coming year, numerous frame platforms will be made from low-emission aluminum that meets the requirements of our new sourcing policy. We expect the aluminum sourced to make frames, components, and accessories will produce only about a quarter of the emissions of previous materials, which will have a massive impact on Trek’s overall emissions.

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