Injection Moulding Machine for Brake and Shift Levers
Plastic brake and shift levers are made on horizontal injection moulding machines, with lever blades and housings in glass-filled nylon, POM for internal ratchet parts and ABS for covers. Cavity count, shot weight and any metal bush inserts set machine size. Holding the pivot hole round and in position, without weld lines nearby, is the main process point.
Lever parts are small but load-bearing, so selection weighs shot accuracy, insert handling and steady holding pressure over raw clamping force. Pratishna Engineers supplies horizontal injection moulding machines for lever blades, shifter housings and ratchet parts and can recommend a set-up for each.
Manufacturing Brake and Shift Levers?
Send your lever and shifter part drawings, materials and volumes, and Pratishna Engineers will recommend a machine.
Machine Requirements for Brake and Shift Lever Moulding
Levers take hand load at the pivot each time the rider brakes or shifts, so accuracy around the pivot leads the list:
- Accurate shot control for small glass-filled lever blades
- Mould space and safe loading for metal pivot bushes
- Gate placed so weld lines miss the pivot hole
- Low residence time for POM ratchet and pawl parts
- Repeatable holding pressure for tight pivot hole tolerance
- Fine texture on the finger face without flow marks
Recommended Machine for Brake and Shift Levers
Lever blades, shifter housings and ratchet parts are small, and many run on the E Series (75-180 T) in multi-cavity moulds. Longer brake levers in high cavity tools, or moulds with several inserts per shot, may move to the H Series (120-350 T) or the C Series (140-320 T). Barrel size should suit the small shots to protect POM from overheating.
Not Sure Which Machine You Need?
Share your lever, housing and insert details for a machine match.
Why Choose Pratishna Engineers?
- Application-Based Machine Selection
- In-House Engineering & Manufacturing
- Multiple Machine Series
- Production-Focused Solutions
- End-to-End Technical Support
- Industry-Specific Solutions
- Machine Lifecycle Support
Injection Moulding Machine Buyer Resources
Download practical resources to help you select, size and specify the right machine.
Horizontal Injection Moulding Machine Selection Guide
A step-by-step guide covering the key inputs needed to select the right machine: product weight, projected area, number of cavities, plastic material, required clamping force, shot / injection capacity, mould dimensions, production quantity, cycle time and automation requirement.
Download PDFPDF · 265 KB
How to Calculate Clamping Force for an Injection Moulding Machine
A clear methodology that explains how clamping force is calculated, covering projected area, injection pressure, safety factor, number of cavities and material considerations.
Download PDFPDF · 363 KBBicycle Components & Machine Guide
A guide to Bicycle components, covering pedals, mudguards, grips, reflectors, bottle cages, saddle bases and levers. It explains glass-filled nylon, PP and PMMA, drying, cosmetic finish, and how to match each part to a suitable machine.
Download PDFPDF · 223 KB
FAQs / Buyer Questions
Questions we hear from lever and shifter part makers.
Which Injection Moulding Machine Is Used to Make Brake and Shift Levers?
Small horizontal machines, often in the E Series, run many lever and shifter parts. Larger brake levers, high cavity tools or insert moulds can go to the H or C Series. Matching barrel size to the small shot matters as much as tonnage.Can Metal Bushes Be Moulded Into the Lever?
Yes. A brass or steel pivot bush can be placed in the mould as an insert, so the lever forms around it. The mould needs locating pins for the bush, and preheating the insert can reduce stress in the surrounding nylon.Why Is POM Used for Shifter Internals?
POM is stiff, slides with low friction and holds small teeth well, which suits ratchets, pawls and index wheels. It is sensitive to overheating, so keep residence time short and purge the barrel before stopping.
Are Glass-Filled Nylon Levers Strong Enough?
For many kids’, city and budget cycles they are, provided the design has generous radii at the pivot and the material is dried well. Weld lines and undried nylon are common causes of lever failure at the pivot.Can Pratishna Recommend a Machine for My Brake or Shift Lever?
Yes. Share drawings or samples of the lever, housing and ratchet parts, materials, part weights, inserts, cavities and quantity, and Pratishna Engineers will recommend a suitable machine.Does the Machine Suit Other Bicycle Control Parts Too?
Yes. Similar machines can mould derailleur pulleys, cable end caps, bell housings and handle grips, depending on the mould and material.
Technical Disclaimer
Disclaimer: The information provided in this webpage is for general informational and educational purposes only. It is based on technical references and industry information available at the time of preparation and may be subject to change. It does not constitute engineering, technical, commercial or professional advice, nor does it constitute a quotation, specification, warranty or contractual commitment by Pratishna Engineers.
Actual injection moulding machine and process requirements vary according to the component design, material, mould, production volume, machine configuration and operating conditions. The information, examples, calculations and recommendations provided should be independently evaluated and verified for the specific application before making any equipment, process or production decision. Information obtained from third-party sources remains subject to the accuracy and limitations of those sources.
Limitation of Liability: Pratishna Engineers makes no representation or warranty, express or implied, regarding the completeness, accuracy or suitability of the information for any particular application. To the extent permitted by applicable law, Pratishna Engineers shall not be liable for any loss, damage, cost or consequence arising from reliance on or use of the information contained in this webpage. Final machine selection, configuration and application suitability should be confirmed with Pratishna Engineers based on complete and accurate project requirements.
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Planning a New Injection Moulding Project?
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