Pedals

Automotive & Industrial Application

Plastic Pedal Injection Molding – Accelerator, Brake & Clutch Pedal Components

A pedal is one of the few plastic parts a driver touches with full body weight every day. It has to stay stiff under load, survive millions of actuations, hold the sensor alignment of a drive-by-wire module and still feel solid underfoot. Ming-Li Precision builds the molds and molds the parts for plastic accelerator pedals, brake and clutch pedal arms, pedal pads and pedal-module housings – from DFM and Moldflow simulation through in-house tooling to IATF 16949 series production in Taichung, Taiwan.

Replacing steel stampings and die-cast parts with glass-fiber-reinforced engineering plastics cuts weight, removes welding and painting steps and lets ribs, bosses, clips and textures be molded in one shot.

IATF 16949

Automotive quality system, PPAP & full lot traceability

Moldflow DFM

Filling, warpage & fiber-orientation simulation before steel is cut

Gas Assist & 2K

Hollow, rigid pedal arms and soft-touch two-shot pads

ZEISS X-Ray CT

Non-destructive check of voids & inner geometry

Accelerator Pedal Arms

Drive-by-wire (E-gas) pedal levers with integrated pivot hub, sensor coupling and return-spring seats, molded in PA66-GF or PPA-GF.

Brake & Clutch Pedals

Structural plastic pedal arms and hybrid metal-plastic designs, with steel bushings or reinforcements secured by insert molding.

Pedal Pads & Covers

Anti-slip ribbed pads with mold-textured surfaces, or two-shot pads combining a rigid core with a TPE/TPV grip layer.

Pedal Module Housings & Brackets

Mounting brackets, sensor housings and covers with tight positional tolerances for Hall-effect / position-sensor alignment.

Industrial & Medical Foot Controls

Foot switches and pedal bodies for machinery, agricultural vehicles and medical / dental equipment where insulation and cleanability matter.

Bicycle & Fitness Pedals

Lightweight pedal bodies with molded traction patterns, metal spindle inserts and integrated reflector pockets.

Why Switch from Metal to Plastic Pedals?

• Lower weight – every gram saved helps range in EVs and fuel economy in ICE vehicles.
• Fewer parts, fewer operations – clips, stops, bearing seats and labels molded in; no welding, machining or painting.
• No corrosion – stable in humid, salty and wash-down environments.
• Electrical insulation – ideal next to sensors and wiring in electronic pedal modules.
• Design freedom – topology-optimized rib networks put material only where the load path needs it.
• Repeatable cost – once the mold is qualified, part-to-part consistency is excellent across high volumes.

Moldflow & Fiber Orientation

We simulate filling, packing and warpage to set gate location, keep weld lines away from high-stress zones and align glass fibers with the bending load of the arm.

Rib Design & Pivot Hubs

Uniform wall thickness, triangulated ribs and precisely round bearing seats keep the pivot free of sink marks and ovality, so the pedal feel stays consistent over its lifetime.

Surface Texture & Grip

Mold-etched or laser textures on the pad give a premium look and reliable grip, while hiding flow lines typical of fiber-filled materials.

Molding Technologies for Pedal Systems

• Gas-Assist Injection Molding – hollow, lightweight and rigid pedal arms without sink marks.
• 2-Shot / 2K Molding – rigid pedal body plus soft-grip pad in a single process, no gluing.
• Insert Molding & Overmolding – steel bushings, shafts, nuts and magnets embedded for hybrid metal-plastic pedals.
• Heat & Cool molding – improves surface quality on fiber-filled visible parts.
• In-house mold manufacturing – tooling designed and built in our own toolroom for fast iterations and long-term maintenance.

01

RFQ & DFM

Design review, material advice

02

Moldflow

Gate, warpage, fiber orientation

03

Mold Making

In-house design & machining

04

Trial & Metrology

T1 samples, CT & 3D reports

05

PPAP

Validation & approval

06

Mass Production

SPC, packing & global shipping

Electronic accelerator pedal module

GF-reinforced pedal arm

Textured anti-slip pedal pad

Are plastic accelerator and brake pedals strong enough?

Yes – when designed correctly. Glass-fiber-reinforced polyamides with an optimized rib structure, correct fiber orientation and well-placed weld lines are widely used for accelerator pedals and increasingly for brake and clutch pedals. Hybrid designs with insert-molded steel can be used where loads are highest.

Which material is best for an injection molded pedal arm?

PA66 GF30–GF50 is the most common choice. PPA-GF is selected when lower moisture absorption or higher temperature stiffness is needed. We recommend the grade after reviewing your load cases and OEM material specifications.

Why use gas-assist molding for pedals?

Gas assist hollows out thick sections of the arm, eliminating sink marks and internal voids, reducing weight and cycle time, and creating a closed tubular section with high bending stiffness.

What do you need for a pedal quotation?

Please send 3D data (STEP/IGES), 2D drawings with tolerances, material specification, annual volume and any test requirements. Our engineers will reply with a DFM review and a tooling and part quotation.