Optimizing Brake Lever Design for Electric Two-Wheelers: A Comparative Study of 3D Printed Polymers

Optimizing Brake Lever Design for Electric Two-Wheelers: A Comparative Study of 3D Printed Polymers | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Optimizing Brake Lever Design for Electric Two-Wheelers: A Comparative Study of 3D Printed Polymers Ganesh Aher, Suhas Gade, Bhardwaj Kulkarni, Ajinkya Satdive, Saurabh Tayde This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5396565/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract The utilization of 3D printing technology has extended its reach across diverse fields, including aerospace, healthcare, the food industry, and construction. This research aims to develop a lightweight brake lever for an electric two-wheeler using fused deposition modelling (FDM) technology, replacing traditional metallic materials with a polymer to reduce both cost and weight. The brake lever was designed using Solid Edge software, converted into a .stl file using Anycubic Slicer, and printed with polylactic acid (PLA) material via the FDM process. Tensile tests were conducted on samples per ASTM D638 standards. Additionally, materials like ABS, polycarbonate, and polypropylene were evaluated using ANSYS software for their suitability as brake lever materials. This study presents a comprehensive approach to utilizing FDM technology for developing critical automotive components, showcasing significant advancements in cost-efficiency and weight reduction. Additive Manufacturing Fused Deposition Modeling (FDM) Brake lever Polylactic acid (PLA) ANSYS software Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5396565","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":374445863,"identity":"433e1f87-834a-4e0a-b802-e0c235148390","order_by":0,"name":"Ganesh Aher","email":"","orcid":"","institution":"Maharashtra Institute of Technology, Aurangabad, Maharashtra","correspondingAuthor":false,"prefix":"","firstName":"Ganesh","middleName":"","lastName":"Aher","suffix":""},{"id":374445864,"identity":"89b7decc-4568-43c8-82fd-df443a67e941","order_by":1,"name":"Suhas Gade","email":"","orcid":"","institution":"Maharashtra Institute of Technology, Aurangabad, Maharashtra","correspondingAuthor":false,"prefix":"","firstName":"Suhas","middleName":"","lastName":"Gade","suffix":""},{"id":374451128,"identity":"67c11530-05f1-434a-a0a2-2b14124dc383","order_by":2,"name":"Bhardwaj Kulkarni","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA7klEQVRIiWNgGAWjYBACAx4eNiDFDMTnPz4Akjx8JGg5YGwA0sJGghYGMwkQSVCLOc/ZYw9+7rFO7G88kFb5NcdOho2B+eGjG3i0WPb2pRv2PEtPnHHgwLHbstuSgZayGRvn4HPYeR4zCZ4Dh3MbDhxsuy25jRmohYdNmpAWyT9ALfMPHGYrltxWT4SWsz1m0iBbNhw4xsb4cdthwlose86lScscSK/feOAMszTjtuM8bMwE/GLOk3tM8s0Ba2O5G2cYP/7cVm3Pz9788DE+LQggcYCBmQfEYCZKOQjwNzAw/iBa9SgYBaNgFIwkAACcWkweOE6zggAAAABJRU5ErkJggg==","orcid":"https://orcid.org/0000-0001-9718-9740","institution":"Chamber of Marathwada Industries and Agriculture, Aurangabad, Maharashtra, India","correspondingAuthor":true,"prefix":"","firstName":"Bhardwaj","middleName":"","lastName":"Kulkarni","suffix":""},{"id":374451541,"identity":"51d8dfe4-97dd-4553-9f0d-e65cd7e70d70","order_by":3,"name":"Ajinkya Satdive","email":"","orcid":"https://orcid.org/0000-0002-3331-9857","institution":"Institute of Chemical Technology, Jalna, Maharashtra, India","correspondingAuthor":false,"prefix":"","firstName":"Ajinkya","middleName":"","lastName":"Satdive","suffix":""},{"id":374451766,"identity":"b1363a9a-a728-4a40-9942-d34254d96117","order_by":4,"name":"Saurabh Tayde","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA90lEQVRIiWNgGAWjYLACxoYDYFqCoYKBB8xKIEYLD1jLGQYeHtK0MLYxQK3BA+Tbz5h9+LnjDoM9+xnDGx/nbZOxZ2B+/OFBDW4tBmdyjGf2nnkGdFCOseXMbbeBDmMzk0g4hkcLQ44xA2/bYaB7csykecFaGMwYEtjwOKz/jTHjX5AW/jdm0n/ngLSwf/6Q8A+PZ27kGDODbZEA2sLYANLCYyCR2IbHYTeeFTPLnjnMwwNkWPYcA2o5zFMmkdiHz2HJmxnf7jgsx96fvPHGj5rb9uzt7Zs//viGx2FQAPQ0hwGEyUxYNQywPyBe7SgYBaNgFIwoAABf305DHtFl0QAAAABJRU5ErkJggg==","orcid":"https://orcid.org/0000-0001-9415-2184","institution":"Maharashtra Institute of Technology, Aurangabad, Maharashtra","correspondingAuthor":true,"prefix":"","firstName":"Saurabh","middleName":"","lastName":"Tayde","suffix":""}],"badges":[],"createdAt":"2024-11-05 15:13:09","currentVersionCode":1,"declarations":{"humanSubjects":false,"vertebrateSubjects":false,"conflictsOfInterestStatement":false,"humanSubjectEthicalGuidelines":false,"humanSubjectConsent":false,"humanSubjectClinicalTrial":false,"humanSubjectCaseReport":false,"vertebrateSubjectEthicalGuidelines":false},"doi":"10.21203/rs.3.rs-5396565/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-5396565/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":68478255,"identity":"8c330f21-12a6-4bda-8f92-2242054b00aa","added_by":"auto","created_at":"2024-11-07 16:29:27","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":613385,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-5396565/v1_covered_750c0888-364c-49ad-83ed-61a22a8c8245.pdf"}],"financialInterests":"The authors declare no competing interests.","formattedTitle":"\u003cp\u003e\u003cstrong\u003eOptimizing Brake Lever Design for Electric Two-Wheelers: A Comparative Study of 3D Printed Polymers\u003c/strong\u003e\u003c/p\u003e","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Additive Manufacturing, Fused Deposition Modeling (FDM), Brake lever, Polylactic acid (PLA), ANSYS software","lastPublishedDoi":"10.21203/rs.3.rs-5396565/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-5396565/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe utilization of 3D printing technology has extended its reach across diverse fields, including aerospace, healthcare, the food industry, and construction. This research aims to develop a lightweight brake lever for an electric two-wheeler using fused deposition modelling (FDM) technology, replacing traditional metallic materials with a polymer to reduce both cost and weight. The brake lever was designed using Solid Edge software, converted into a .stl file using Anycubic Slicer, and printed with polylactic acid (PLA) material via the FDM process. Tensile tests were conducted on samples per ASTM D638 standards. Additionally, materials like ABS, polycarbonate, and polypropylene were evaluated using ANSYS software for their suitability as brake lever materials. This study presents a comprehensive approach to utilizing FDM technology for developing critical automotive components, showcasing significant advancements in cost-efficiency and weight reduction.\u003c/p\u003e","manuscriptTitle":"Optimizing Brake Lever Design for Electric Two-Wheelers: A Comparative Study of 3D Printed Polymers","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-11-06 08:14:38","doi":"10.21203/rs.3.rs-5396565/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"9fe67ee9-a3ed-4f46-8ea9-9da31dfbdf59","owner":[],"postedDate":"November 6th, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2024-11-06T08:14:39+00:00","versionOfRecord":[],"versionCreatedAt":"2024-11-06 08:14:38","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-5396565","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-5396565","identity":"rs-5396565","version":["v1"]},"buildId":"qtupq5eGEP_6zYnWcrvyt","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}