Light, durable, compact - Tubolito and the bicycle tube revolution

With Ákos Kertész and Christian Lembacher – two passionate mountain bikers and at the same time experts in high-tech materials from the smartphone industry – it was the moment at the side of the trail when they once again had to change a traditional butyl tube. While the bike patiently stood upside down, an obvious question arose: "How is it possible that the cycling world has long been celebrating electronic shifting, hydraulic disc brakes, and ultra-light carbon frames – but remains stagnant when it comes to the simple rubber tube?"

The two Viennese knew from their professional daily life what is possible when material research and engineering intertwine. For renowned smartphone manufacturers like Apple and Nokia, they had developed ultra-thin membranes for speakers – components that need to be extremely light, flexible, and simultaneously stable. So why not in the cycling sector as well?

What followed was not a quick shot, but rather several years of development work. With the perspective of a mechanical engineer and the knowledge of a chemist, Kertész and Lembacher set out to find a material superior to the classic bicycle tube: lighter, more compact, more durable.

The result is called Tubolito. And even though they did not invent the material Thermoplastic Polyurethane (TPU), they were the first to bring it to a new level of relevance and visibility in the cycling segment.

History of TPU tubes

Before we dive deeper into the Tubolito story and the company profile, it’s worth taking a quick look at the material itself.
Many people associate TPU primarily with racers, weight weenies, or connoisseurs. However, depending on the blend and dimensions, TPU offers undeniable advantages not only to the performance-oriented crowd mentioned above but also brings tears of joy to commuters, touring cyclists, or even BMX riders—especially when it comes to pack size, puncture resistance, or simply hassle-free handling during tube changes.

TPU stands for thermoplastic polyurethane—a material that sits somewhere between rubber and high-tech plastic. Flexible, tear-resistant, moldable, extremely lightweight, and surprisingly durable. It has long been a standard in the industry when traditional materials reach their limits—so it’s only logical that sooner or later it would also be repurposed for bicycle tubes. 

► Weight: TPU tubes are true minimalists. A classic butyl tube usually weighs between 100 and 120 grams, while a Tubolito – depending on the model – can weigh even less than 23 grams (e.g., S-Tubo Road). For weight enthusiasts, this is the material of choice.

► Packing size: TPU tubes can be folded extremely compactly – ideal for saddle bags, jersey pockets, or even the tiniest frame bags.

► Air retention: Roughly comparable to thick butyl. You don't need to keep pumping them up – unlike latex or TLR systems.

► Rolling resistance: Tests show that TPU tubes often produce measurably less rolling resistance than butyl. While they don't quite reach the level of latex, they come very close – with significantly better everyday usability.

► Puncture resistance: The high tear resistance and tough nature of TPU make it more resistant to punctures and pinch flats.

► Sustainability: Many TPU tubes (e.g., from Tubolito or Schwalbe) are fully recyclable – an ecological advantage that one can proudly embrace.

► Assembly: TPU tubes are more sensitive during installation than regular butyl tubes. Those who handle tire levers roughly risk fine tears – and thus later leaks.

► Puncture repair: Unlike butyl, patching TPU on the go is possible but not always reliable. Many users prefer to carry a spare tube and repair the damaged one later at home.

► Ride feel: Some riders report a slightly "harder" ride feel. TPU tubes dampen less than latex and feel stiffer than butyl. Noticeable? Maybe. Psychological? Definitely.

► Price: TPU is not a bargain. While a butyl tube costs between 6 and 10 euros, TPU models often range from 20 to 40 euros. Therefore, not very interesting for bargain hunters.

The Tubolito GmbH was founded in 2016 by the two Viennese entrepreneurs Ákos Kertész and Christian Lembacher. With their expertise in mechanical engineering and materials science, they developed innovative bicycle tubes made from thermoplastic polyurethane (TPU), which impress with their lightweight and high robustness.

As a classic startup, they began in a small office in Vienna's third district, developing the first prototypes, which were initially tested on themselves. Step by step, the tubes were introduced in selected specialized bike shops in Vienna and distributed to frequent riders from various cycling clubs. They were tested, destroyed, analyzed, and improved. Gradually, more and more shops took notice, and more and more consumers were riding with the distinctive orange tubes.

Since autumn 2020, the company's headquarters have been located on Pottendorfer Straße in Vienna's 12th district. This is where research, development, marketing, and company management are based. Tubolito currently employs 16 staff members.

The production of the TPU tubes takes place in Sopron, Hungary, near the Austrian border. The location enables efficient manufacturing and logistics within Europe.

Bikeboard: How did you manage to enter the specialized trade market domestically and internationally, as well as the major online shops? Was it a tough battle – or was the market waiting for you?

Tubolito: It was almost a stroke of luck: On one of our road trips, we got in touch with the team from Mountainbiker.at, who used our tubes in mountain bike marathons – and deemed them good. The decisive push came from Martin Rösner, who said: “This would be something for Pancho.” (Editor’s note: This refers to Johann Pöllmann, nickname “Pancho,” managing director of Bike+Sports GmbH – an experienced wholesaler and wheel specialist.)

At that time, Pancho was already distributing TPU tubes from another manufacturer but wasn’t entirely satisfied with their reliability. Consequently, he reacted cautiously at first – until his team riders tested our products themselves in Bad Goisern. The result: Tubolito was added to the assortment, and things started rolling. Since 2016, Bike+Sports has been our exclusive partner in the Austrian specialized trade market.

Shortly afterward, a distribution partner for Germany followed, and major online shops such as Bike24, Bike-Components, and R2-Bike quickly joined in. With our first Eurobike appearance in 2017, the development gained full momentum – today, Tubolito tubes are available worldwide.

Bikeboard: You offer a free replacement for defective X-Tubo tubes within one year. How long do you plan to continue this service – especially as sales continue to grow?

Tubolito: The return rate of the X-Tubo models – which are our particularly robust variants for e-MTB, gravel, and trekking bikes – is remarkably low. In other words, the products deliver on their promises. For this reason, we currently see no reason to discontinue the replacement service.

Although the administrative effort should not be underestimated, a large part of the process is now automated and handled exclusively through prior product registration. This keeps the effort manageable – regardless of how many tubes are sold.

Bikeboard: Are the many new TPU brands and manufacturers from Europe and Asia giving you headaches?

Tubolito: No – that's part of the game. Of course, sometimes you wish for a patent that would protect you permanently. But that's not how the market works, especially not in a high-growth segment like ours.

From the beginning, we knew that sooner or later other providers would push into the market. And to be honest: The fact that more and more manufacturers are now focusing on TPU confirms that we are on the right path. We have created a market that didn’t exist in this form before – now it's up to us to expand our lead. And we are convinced: We are still at the very beginning.

What sets us apart from the competition is not only our experience but also the depth of our portfolio: With S-Tubo, Tubo, and X-Tubo, we cover a wide range of applications – from road bikes to gravel bikes to e-MTBs. With the integrated PSENS system, we also offer an innovative feature that is unique to us.

Additionally, we have strong testimonials – for example, in the BMX race segment, the Hrinkow team, or international UCI riders who rely on our tubes. A real unique selling point is also our 1-year exchange program for X-Tubo models, including systematic analysis of the returned tubes – this is not just about service but also about continuous product development.

And last but not least, we are long established on the OEM level – with partners like Brompton, Bianchi, or Canyon. Unfortunately, we are still missing KTM – of all places, Austria and Orange! But well: Some things just take a little longer. For us, it remains a matter close to our hearts.

Bikeboard: Does your focus remain on bicycles – or are you already considering using TPU in other areas?

Tubolito: The bicycle sector clearly remains our main focus – both in terms of development and sales. Nevertheless, there are already initial projects beyond this: For a major motocross manufacturer, we produce red TPU tubes as an OEM solution, and aftermarket products in this area are also in planning.

In addition, we are working on further innovations – including around our PSENS system. We see potential for new applications here, but we remain committed to bicycles as our core market.

Bikeboard user punkti asks: How important is the topic of recycling to you – aside from marketing claims? And what is the actual recycled content in your tubes?

Tubolito: Recycling is a genuine concern for us – not just as a sales argument, but as part of long-term product responsibility. We are working on this at two levels: Firstly, through our take-back system in specialist retail stores. In this system, we accept not only our own tubes but also those of other manufacturers, provided they are made of TPU.

Secondly, we consistently recycle waste from our own production (post-industrial waste). This is processed by a partner company into new TPU granulate, which is then – after coloring – primarily used in other industries, e.g., for the production of shoe soles.

Currently, this recycled material is not yet being used in the production of our tubes – the recycled content is therefore currently zero percent. Smaller amounts of the granulate are being further utilized in our research department with the goal of eventually producing new tubes from recycled material. This is a long-term goal that we are actively working toward.

In short: We are not yet where we want to be – but we are doing more than just talking about it.

Bikeboard user punkti asks: Since you produce in the EU – how are you addressing the PFAS ban issue?

Tubolito: The PFAS issue does not currently pose a problem for us. Our TPU tubes do not contain any PFAS, and we do not use any such substances in production. Therefore, the topic does not affect us either in manufacturing or in the product itself.

Bikeboard user bbkp writes: I am somewhat unhappy about the glued-in valve cores. With a pneumatic sealant – similar to a threadlocker – this worked perfectly for me, and the core could still be replaced.

Tubolito: We understand the desire for replaceable valve cores – and indeed tested various adhesives during the development phase. However, we also had to take global requirements into account: Our tubes are used in regions with extremely high humidity, intense heat, severe cold, and sometimes significantly higher air pressure than in Central Europe.

In the end, a high-strength adhesive proved to be the best solution – not only in terms of absolute air tightness but also regarding reliable curing with the shortest possible waiting time. For maximum functionality and worldwide reliability, we deliberately chose this option – even though it means that replacing a valve core afterward is no longer possible.

Bikeboard user lizard asks: How long can I use a Tubolito? I've had it in my road bike/gravel bike for over two years – I just don't want it to implode on a descent due to aging.

Tubolito: No worries – there is no "expiration date" in the classic sense for our tubes. TPU is an extremely aging-resistant material and, unlike butyl or latex, does not show typical embrittlement effects over time.

As long as the tube shows no damage and retains its seal, there is no technical reason against continued use – even for several years. Regular visual and pressure checks, of course, never hurt.

Bikeboard user BikeBär asks: Is it just a subjective impression or actually justifiable that Tubolito/TPU, due to its non-elastic properties, has a lower tendency for sudden failure and better run-flat characteristics? That would be an interesting selling point.

Tubolito: Your observation is indeed understandable - and technically justifiable in certain scenarios. TPU behaves significantly tougher and more tear-resistant than butyl or latex. This is also evident in independent puncture tests, where our tubes regularly achieve very good results. Especially at low air pressure, TPU offers higher puncture resistance - something that would be much more critical with traditional butyl.

However, even for us, the following applies: In the case of a classic snakebite (i.e., an impact puncture due to excessive impact and too low air pressure), anything is possible - including a sudden air loss. The material properties of TPU can, in such cases, favor a slightly less abrupt leak but do not guarantee a true "run-flat" effect in the literal sense.

In short: Yes, TPU can react more robustly in certain cases - especially with slow damage or localized punctures. However, the topic of "run-flat characteristics" is complex and highly dependent on pressure, tire type, and load. A real advantage - but not a free pass.

Bikeboard user hermes asks: Why green valves anyway? They really don't match any bike. Red or blue would surely sell better.

Tubolito: The green valves with the flip-flop effect were intended as a limited edition – a small splash of color for those who prefer something a bit more individual. And surprisingly: They were actually well received. Sure, they don’t match every bike – but that’s exactly why we offer our black valves, which work universally and are the first choice for most road cyclists.

Will red, blue, or other colors follow in the future? We’re not ruling it out. Who knows – maybe one day the valve shelf will get really colorful.

Bikeboard user ventoux asks: What improvements and further developments are you still working on? Where does Tubolito itself see potential for improvement?

Tubolito: In short: There are still adjustments to be made everywhere – and that’s exactly what we’re continuously working on. Our goal is to further optimize all properties: even more resistant to punctures, even more airtight, even lighter – and, looking ahead, also more attractive in terms of price.

A lot of development work is currently happening behind the scenes, especially in the areas of material formulations, manufacturing tolerances, and valve technology. And new features – such as further developments of PSENS – are also on the list.

We are convinced that TPU as a material still has a lot of potential – and we are far from the end of its development.

Even more answers to frequently asked questions as well as all product variants can be found on tubolito.com.