Case-Study “ClipClap”

When developing new products, the choice of materials, functionality and the requirements of the intended application play a key role. This was also the case for the development of the ‘ClipClap’, a product from the start-up ClipClapCycling. In this case study, we demonstrate how BARLOG Plastics, through the selection of suitable materials and comprehensive development services, helped bring the product to market quickly, safely and cost-effectively.

Project description

The ‘ClipClap’ project is a clip-in pedal adapter for bicycles, developed in collaboration with BARLOG Plastics.

BARLOG Plastics supported the implementation of the project with services in the areas of material selection, consultancy, design, simulation, prototype manufacturing and pre-series production.

The clip-in pedal adapter can be slipped over standard shoes, enabling them to be used with clip-in pedals. This makes it possible to use clip-in pedals even without specialised cycling shoes and broadens the range of applications for such cycling systems.

Material selection

KEBALLOY® ECO R-PC FE 230202 was used for this project. This is a material based on recycled polycarbonate, which is obtained from sources including plastic sheets and water bottles.

The material offers the transparency required for the application as well as the mechanical properties needed for the intended use.

Development services

BARLOG Plastics supported the customer in selecting the material for the two pedal variants, ‘Road’ and ‘Explore’, using single- and two-component injection moulding processes.

In addition, a manufacturing and materials concept was developed that combines the customer’s design requirements with the technical requirements of subsequent production.

As part of the component development process, the models were optimised for plastic moulding. For the ‘Explore’ variant, special geometric elements were also integrated to ensure reliable injection of the soft component in the two-component injection moulding process.

In addition, BARLOG Plastics carried out injection moulding simulations. These simulations enabled potential filling and warpage issues to be identified at an early stage and addressed before tooling was manufactured. This helped to prevent potential quality deviations, particularly in the area of the logo.

Prototypes and pre-series production

A total of four prototype tools were manufactured from aluminium, and 500 components have already been produced for trade fair and promotional activities. This enabled potential users to test the product under real-world conditions and gain initial practical experience. The insights gained were directly incorporated into the further optimisation of the product.

Small-batch production

The aluminium moulds for prototype production were designed from the outset to be suitable for the pre-series phase and the start of series production. This enabled up to 5,000 components to be manufactured per year.

The experience gained from pre-series production is passed on to the subsequent series supplier in order to lay the foundations for an efficient production start-up and stable manufacturing of larger quantities.

Conclusion

Thanks to the close collaboration between the customer and BARLOG Plastics, the series production start-up was achieved within less than a year of the project’s launch.

Another focus of the project was on collaboration with regional partners, as well as on taking into account the customer’s defined requirements regarding material selection and product concept. These requirements were incorporated into the design and optimisation of the product as early as the initial development phase.

The project demonstrates how BARLOG Plastics can support customers in launching new products through its expertise in materials, development services and the manufacture of prototypes and pre-series runs. The combination of material selection, design, simulation and manufacturing enabled the project to be implemented quickly, reliably and cost-effectively.

Where materials based on recycled content were used for the product, their processing properties and suitability for the application could be assessed as early as the development phase.