Case-Study “ClipClap”

“ClipClap” – Sustainable project support from idea to series production.

Sustainability and the reduction of the CO2 footprint are becoming increasingly important in the development of new products. This interest was also essential in the creation of “ClipClap”, a product of the start-up ClipClapCycling. In this case study, we show how BARLOG Plastics helped bring the product to market quickly, safely and cost-effectively through the right material selection and development services.

Project description

The “ClipClap” project is a clipless pedal adapter for bicycles that was developed in collaboration with BARLOG Plastics. BARLOG Plastics’ expertise to realize this project were material development, consulting, design, simulation, prototyping and pre-series production. The clipless pedal adapter can be pulled over any commercially available shoe, turning it into a clipless shoe. This makes clipless pedals suitable for everyday use and thus contributes to sustainable mobility.

Material selection

KEBALLOY ECO R-PC FE 230202, a recycled polycarbonate (PC) from plates and water bottles, was used for this project. This material is transparent and recyclable.

Development services

BARLOG Plastics advised on the material selection for the two pedal variants “Road” and “Explore” in 1K and 2K injection molding, developed a concept and implemented the customer’s design wishes. In addition, the models were optimized to suit the plastic and, for the “Explore” version, special features were added to the component geometry for perfect gating of the soft component in the 2K process. In addition, injection molding simulations were also carried out, with the help of which warpage & filling problems in the logo area could be avoided.

Prototypes and pre-series

A total of four prototype molds have been manufactured from aluminum and 500 components have already been produced for trade show and promotional activities. This allows end customers to actively test the product and start initial field trials.

Small series

The aluminum molds used for prototyping were designed from the start
designed from the outset so that they can be used for the pre-series phase
up to 5,000 units per year for the pre-series phase and series
year. The experience gained from pre-series production is then
transferred to the future series supplier, in order to ensure the fast and
and trouble-free production of large quantities.

Conclusion

The start of series production after a successful market launch was achieved in less than a year thanks to the support of BARLOG Plastics and the agile collaboration with the customer. The customer wanted regional partners for the implementation of all components. Circular economy was desired from the beginning and taken into account when fine-tuning the concept. This project clearly demonstrates how BARLOG Plastics can help bring a product to market quickly, safely and cost-effectively by providing high-quality materials and development services. It also underlines BARLOG Plastics’ commitment to sustainability through the use of recycled materials.