Posted by Screef The resin they cast around it that gives it strength. For the 50 to 100$ manufacture cost you may as well make it out of metal. Cool, but not practical.
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Have you ever ordered or worked with bike materials?(tubing, parts, metal sheet materials and such). I have and its not cheap, easy or particularly profitable.
The labor is intensive and requires specific machinery, frame jigs and tooling in addition to materials availability, qualified machinists and welders. Then you have the OEM distributors and overhead costs.
Cardboard can be found anywhere in the world including third world countries, hence the use of that specific material.
Doesn't sound so easy now eh?