Air pollution from motorized vehicles poses global health and environmental challenges, prompting a shift to zero-emission alternatives. While electric cars dominate attention, e-bikes are revolutionizing transportation by offering faster, eco-friendly travel. With the e-bike market projected to reach $149 billion by 2032 (14.6% CAGR), advancements in design and materials are key to meeting demand for powerful, efficient, and safe models like speed pedelecs.
Speed pedelecs, capable of reaching up to 45 km/h with engines as powerful as up to 4,000W, require advanced material solutions to ensure safety and performance. High-voltage components in these e-bikes demand insulating materials with superior electrical and thermal properties to prevent electrical tracking, overheating, and fire risks.
Envalior’s Xytron® PPS is a leading choice for these applications, offering exceptional flame resistance, chemical resistance, and stiffness at high temperatures. Similarly, Arnite® PET and Arnite® & Pocan® PBT provide the strength and dimensional stability required for manufacturing thin-walled, high-performance engine parts in a cost-effective manner.
As power and torque increase in e-bike motors, manufacturers are often looking for higher performing materials for motor gears than polyoxymethylene (POM) can offer. An example of such higher performing materials is Stanyl® PA46. This material delivers exceptionally good temperature performance, wear resistance, low friction and high fatigue strength, making it a good and cost-effective solution for demanding gear components required to perform at high operating loads and during long times.
Designing more powerful e-bike batteries requires materials that balance compact size with high energy capacity, without compromising safety. Larger, more energy-dense batteries increase the risk of overheating and chemical exposure, especially if damaged.
Envalior offers lightweight, durable, flame-retardant materials with high Comparative Tracking Index (CTI) ratings to meet the stringent safety requirements of battery housings, connectors, and mechanical fixations. These solutions ensure best-in-class resistance to heat and flame, reducing the risk of fire during charging, even in enclosed spaces like homes or garages.
Envalior’s advanced materials are designed to meet the challenges of modern e-bike manufacturing, delivering safety and durability performance. Here are the key benefits of our innovative solutions:
As the e-bike industry evolves, consumers expect safer, more powerful and reliable models that support eco-friendly commuting. Envalior continues to develop innovative material solutions that enable manufacturers to overcome challenges and seize new opportunities in electrified transportation.
Ready to power the future of e-bike innovation? Envalior’s advanced materials are here to help you create safer, more efficient and durable e-bike systems and components. Contact us today about how we can help in any of your current and future developments.
Application Expert, Gears & Bearings, Envalior
Adnan Hasanovic is application expert for actuators and bearings at Envalior. In his global role he focuses on tribological applications, such as gears, bearings, and wear and friction bushings, as well as structural applications including actuator housings and covers. Adnan also supports global Envalior activities in existing and new application fields. He joined Envalior after he completed studies of mechanical engineering. Before joining Envalior, Adnan worked as CAE engineer and application development engineer.
24 February 2025
2 min read
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