Project Background

In high-performance bicycle design, the brake lever is not only a key control component but also directly impacts riding safety and handling precision.

Traditional materials often fail to balance lightweight and strength, whereas long fiber reinforced thermoplastics offer outstanding rigidity, impact resistance, and fatigue durability, making them ideal alternatives to metals or short-fiber plastics.

Materials such as PA66 with long carbon fiber or TPU with long glass fiber can significantly enhance structural performance while improving molding efficiency and surface quality—perfectly aligning with modern demands for safety, lightweight design, and aesthetics.

Customer's Project

The products shown above are two types of bicycle brake levers, respectively manufactured using PA66 filled with 40% long carbon fiber (without color masterbatch) and polyether-based TPU filled with 50% long glass fiber (with black color masterbatch).

Each material offers unique advantages, allowing customers to choose the most suitable option based on their specific performance requirements.

Material 1: TPU-LGF50-BLK
Material:

Polyether-based TPU filled with 50% long glass fiber (with black color masterbatch)

Key Features:
1. Finished in a deep matte black tone, this version delivers a sleek, modern look with a smoother surface texture.

2. Offers a slightly flexible feel for enhanced grip comfort, while still maintaining significant structural integrity thanks to the high glass fiber content.

Performance Highlights:
1. Exceptional impact resistance and abrasion resistance

2. Improved surface comfort, ideal for frequent contact or high-vibration environments

3. Perfect for applications where tactile feel, flexibility, and weather resistance are key considerations

Click the material image to see details

Material 2: PA66-LCF40-NAT
Material:

PA66 filled with 40% long carbon fiber (no color masterbatch)

Key Features:
1. This brake lever features a natural finish that highlights the carbon fiber texture, clearly visible on the surface.

2. The unique grain of the long carbon fibers offers a premium look and feel, echoing the aesthetics of carbon fiber parts in professional cycling equipment.

Performance Highlights:
1. Excellent rigidity and strength, ideal for high-load applications

2. Superior heat resistance and dimensional stability

3. Best suited for riders or product designs that demand lightweight structural strength and a carbon-tech appearance

Click the material image to see details

Advantages

Lightweight Metal Replacement
1. Both PA66-LCF40-NAT and TPU-LGF50-BLK offer significant weight reduction compared to traditional aluminum alloy or steel brake levers.

2. PA66-LCF40-NAT provides high stiffness at low density, reducing overall component weight without sacrificing mechanical strength.

3. This lightweight solution helps improve riding efficiency and handling agility, especially in competitive or endurance cycling.

Integrated Cost Efficiency
1. Long fiber thermoplastics allow one-step injection molding, eliminating the need for secondary assembly or metal machining.

2. This streamlines production and reduces tooling complexity.

3. Compared with aluminum or engineering plastics, the total cost is significantly optimized.

Durability in Harsh Conditions
1. These materials are designed to perform reliably under outdoor and high-vibration environments, such as mountain biking or long-distance rides.

2. PA66 offers superior resistance to fatigue, heat, and moisture.

3. TPU brings added flexibility, shock absorption, and grip comfort, ideal for frequent user contact.

Design Flexibility & Customization
1. LFT-G supports custom formulations tailored to customer needs:

2. Color options (natural carbon fiber texture, matte black, etc.)

3. Surface finish customization (visible fiber pattern vs. smooth touch)

4. Optional UV or chemical resistance for extended product lifespan

Typical Application Scenarios
High-performance road or mountain bike brake levers

E-bike brake systems requiring vibration damping and rigid control

Ergonomic brake components for urban commuter bikes

Lightweight replacement of metal brake handles in mid- to high-end bicycles

Learn More
If you're exploring material solutions for bicycle components that require a balance of strength, durability, and processing efficiency, our formulations offer reliable, well-tested options.

We welcome you to get in touch for further technical details, sample requests, or to discuss specific application needs.