First all-plastic brake pedal for battery-electric sports car

In a battery-electric sports car, every gram of weight counts. That is why the first mass-production vehicle in this segment is using an all-plastic brake pedal. This safety-critical component has been developed by

In a battery-electric sports car, every gram of weight counts. That is why the first mass-production vehicle in this segment is using an all-plastic brake pedal. This safety-critical component has been developed by BOGE in close cooperation with the LANXESS High Performance Materials (HPM) business unit. It owes its high mechanical strength and very low weight to a thermoplastic composite design. Its structure comprises an insert made from Tepex dynalite, a continuous-fiber-reinforced thermoplastic composite from LANXESS, and several tapes.

The composite structure makes the brake pedal 50 percent lighter than a comparable steel design. The structural component meets the demanding load requirements thanks to the tailor-made fiber-layer construction of the Tepex insert and additional local tape reinforcement.

There are currently four different brake pedal designs in mass production based on an all-plastic version. For all component versions, the load paths are also optimized to suit the various torsion directions.

Photo: LANXESS AG – All-plastic brake pedal for a battery-electric sports car with an insert made from Tepex dynalite, a continuous-fiber-reinforced thermoplastic composite from LANXESS