Bicycle Saddle Injection Moulding

Bicycle saddle injection moulding is a specialized injection process for bicycle saddle main bodies, support structures or protective components. By injecting molten plastic into customized molds, it forms bicycle saddle components that meet ergonomic and mechanical requirements in one go. This process is suitable for producing seats for various types of bicycles such as mountain bikes, road bikes, and urban commuter bikes, with core products including saddle shells, shock-absorbing support blocks, and bottom reinforcement frames.

Its significant advantages lie in three aspects: structural integration (complex support patterns can be formed in one go without subsequent splicing), controllable mechanical properties (impact resistance and fatigue resistance are achieved through material selection and process adjustment), and short production cycle (single mold production time can be controlled within 30-90s, suitable for bulk orders). It is also compatible with various functional plastics such as PP, PA6+glass fiber, ABS, and TPE.

P&M Bicycle Saddle Injection Moulding Introduction

Core Process Steps

1.Raw Material Selection & Pretreatment

Select raw materials based on bicycle saddle functional requirements: PA6+30% glass fiber (high strength, anti-aging) is commonly used for saddle shells, TPE/TPR (high elasticity, skin-friendly) for soft contact layers, and ABS (good rigidity, easy processing) for bottom support structures;

Dry hygroscopic raw materials (such as PA6): Use a dehumidifying dryer to dry at 80-100℃ for 4-6 hours, controlling moisture content below 0.1% to avoid cracking or bubbles after molding;

For two-color/multi-material molding (such as hard shell + soft contact surface), prepare two types of raw materials separately and adjust the temperature compatibility of the barrel.

2. Mold Design & Preheating

The mold adopts a parting surface structure, which needs to include a saddle curved cavity, support rib grooves, mounting holes (for connecting with the frame), and reserve vent grooves (width 0.03-0.05mm, depth 0.8-1.2mm) to avoid surface defects caused by gas retention;

For two-color molded saddles, the mold needs to be equipped with a rotary cavity or two-color injection system to ensure accurate bonding of the two materials;

Preheat the mold to 40-60℃ (adjust according to raw materials: TPE materials need to be slightly lower, PA6+glass fiber need to be slightly higher) to reduce the temperature difference between the melt and the mold and avoid internal stress caused by rapid cooling.

3. Injection Molding & Pressure Holding

Single-material molding: The screw injects molten plastic into the mold cavity at 80-150MPa injection pressure and 30-80mm/s injection speed. The filling process is controlled in two stages (fast filling to 90% of the cavity in the first stage, slow material replenishment in the second stage to avoid flash);

Two-color molding: First inject the hard shell material (such as PA6+glass fiber), and after it is initially shaped (cooling for 10-15s), rotate the cavity or switch the injection system to inject the soft material (such as TPE) to ensure the interface fusion of the two materials;

Pressure holding stage: Maintain 50-100MPa holding pressure for 15-30s to compensate for plastic cooling shrinkage, ensuring the saddle surface is full and free of depressions.

4. Cooling & Demolding

Use a circulating cooling water system to cool the mold. The cooling time is adjusted according to the product thickness (when the saddle thickness is 3-8mm, the cooling time is 20-40s) to ensure the plastic part temperature drops below the heat distortion temperature (e.g., the heat distortion temperature of PA6 is about 70℃);

During demolding, a thimble + top plate combination mechanism is used. Thimbles are evenly distributed in the non-force-bearing area at the bottom of the saddle to avoid local stress and cracking during demolding;

Conduct a preliminary appearance inspection on the demolded plastic parts and reject defective products with scratches, bubbles, or flashes on the surface.

5. Post-treatment & Assembly

Remove the gate and flash on the surface of the plastic part (using an automatic trimming machine or manual grinding to ensure smooth edges without burrs);

Perform texture treatment on the saddle surface (such as laser engraving anti-slip patterns, spraying wear-resistant coatings) to improve the user experience;

Assemble accessories such as metal brackets, shock-absorbing springs, and adjustment knobs, and realize component connection through screw fixing or ultrasonic welding to finally complete the bicycle saddle finished product.

P&M Bicycle Saddle Injection Moulding(Specification)

P&M Bicycle Saddle Injection Moulding Feature And Application

1. Mainstream Application Scenarios

Mountain Bike Saddle：Adopt PA6+glass fiber hard shell + TPE soft layer, and add reinforcement ribs at the bottom to improve impact resistance (can withstand 500N pressure without deformation);

Road Bike Saddle：The whole is made of lightweight ABS material, and the surface is frosted to reduce friction during riding;

E-bike Saddle：Built-in honeycomb shock-absorbing structure, formed by TPE elastic material injection molding to improve comfort during long rides.

2. Technical Innovation Directions

Biobased Plastic Application：Application of biobased plastics: Use PLA+bamboo fiber composite raw materials to reduce dependence on traditional plastics and achieve environmental protection and degradability;

Combination of 3D Printing & Injection Molding：Combination of 3D printing and injection molding: First 3D print personalized saddle cavities, then quickly produce customized products through injection molding;

Smart Sensor Integration：Smart sensor integration: Embed pressure sensors during the injection process to monitor the force distribution of the saddle in real time and optimize the ergonomic design.

Customization Process

Factory&About US

NingBo Plastic Metal Product Co.,Ltd (P&M) is located in Yuyao, the so-called Mould City, Plastic Kingdom, in the southern tip of Hangzhou Bay Bridge,north of Shanghai, the east of Ningbo Port,tight double line of State Road 329 on land, sea and air trafic into a network to facilitate transport.

By the abundant technical strength,scientific management methods and good after-sales service, product deeply trusted and welcomed by customers from all over the world. P&M holds improved system of development and production, to achieve mold design, plastic products manufacturing and automatic production. Our main products is design and manufacturing of plastic mold, plastic product, metal product. 90% products of our enterprise are exported to America, Europe, Germany, Japan, Australia, etc. For many years, the company has been committed to the research of raw materials. The company has its own trademark and dozens of patents, providing more convenient technical support for mold making and product production. P&M started domestic business from 2008,named Shundi Mould Factory. And opened the international market from 2014. We always adhere to the principles of quality first and time first. While providing customers with the highest quality products, try to maximize the production efficiency and shorten production time. We are proud to tell every customer that our company has not lost any customer since its establishment.If there is a problem with the product, we will seek a solution actively and take responsibility to the end.

P&M adheres to market-oriented to the quanlity of life and focus on quality service and continuous development of new products,determined to establish a better corporate image,and our friends at home and abroad to carry a wide range of business exchanges and cooperation, create brilliant.

Packing

Packaging according to your needs

1. By air ,it takes 3-7 days for delivery.

The goods can be shipped by DHL , Fedex , UPS .

2. By sea ,the delivery time is based on your port.

To South East Asian Countries takes about 5-12 days.

To Middle east countries takes about 18-25 days.

To European countries takes about 20-28 days.

To American countries takes about 28-35 days.

To Australia takes about 10-15 days.

To African countries takes about 30-35 days.

P&M Bike parts, centered around children, balances safety, health, and fun, aiming to add a bright color to children's beautiful childhood. We look forward to working together with you to serve our children.

The path of a child's growth is paved with bricks and tiles.

FAQ

1.Who are we?

We are based in Zhejiang, China, start from 2014,sell to North America(30.00%),Southern Europe(10.00%),Northern Europe(10.00%),Central America(10.00%),Western Europe(10.00%),Mid East(10.00%),Eastern Europe(10.00%),South America(10.00%). There are total about 51-100 people in our office.

2.How can we guarantee quality?

Always a pre-production sample before mass production;

Always final Inspection before shipment;

3.What can you buy from us?

Mould, Plastic Product, Metal Product, Dental Product, CNC machining.

4.Why should you buy from us not from other suppliers?

We main do all kinds of 3d design, 3d printing and plastic metal molds tooling and products. We have our own engineer and factory. One-stop supply: 3d design - 3d printing - mold making - plastic injection.

5.What services can we provide?

Accepted Delivery Terms: FOB,CFR,CIF,EXW,FCA,DDP,DDU;

Accepted Payment Currency: USD, EUR;

Accepted Payment Type: T/T,L/C,PayPal,Western Union,Escrow;

Language Spoken:English,Chinese,Spanish,French,Russian.

6.What are the characteristics of your service?

1. Your inquiry related to our products or prices will be replied within 24 hours.

2. Well-trained and experienced staffs to answer all your enquiries in fluent English.

3. Offering the support to solve the problem in the application or selling period.

4. Competitive prices based on same quality.

5. Guarantee samples quality same as mass production quality.