(E-)Brake Pedals

Traditionally, clutch and accelerator pedals have been made from polyamide 6, while brake pedals have typically remained metal due to the high load requirements. However, Envalior has managed to significantly reduce the weight and cost of brake pedals by using their proprietary Akulon and Durethan PA6 materials in combination with advanced hybrid technologies.

For conventional brake pedals that activate a vacuum brake-booster mechanically, Envalior has successfully applied their plastic metal hybrid technology. Plastic metal hybrid pedals run in series production based on overmolding a deep-drawn sheet metal profile and afterwards joining this open profile with a metal top layer to achieve a hollow profile in the final part.

Applying this technology maximizes the mechanical performance while reducing weight to a minimum. In addition, for ultra-lightweighting, overmolded thermoplastic composite solutions have been commercialized, offering the design flexibility of injection molding and the high performance of thermoplastic composites for heavily loaded areas.

In e-Braking (brake-by-wire) systems, Envalior's PA6 materials and comprehensive design expertise have enabled the development of fully plastic injection-molded solutions. These innovations maximize both weight and cost efficiency.