EV Core Components: Jointly Overcoming Special Alloy Challenges with a Leading Chinese NEV Brand
Challenge
In 2019, the NEV industry faced the critical trade-off between “performance upgrade” and “cost reduction.” When a leading Chinese NEV brand sought materials for core powertrain components of its new premium models, it hit an industry-wide pain point: the material needed to meet three strict demands — lightweight design to reduce vehicle energy consumption, resistance to extreme conditions with stable performance at ≥200℃ and under high-frequency charging and discharging, and cost-effectiveness for mass production.
After visiting over 300 steel mills nationwide, the brand was still stuck: available materials either had insufficient performance, such as heavy alloys reducing driving range or rapid aging at high temperatures, or relied on expensive imported substitutes, creating a dilemma between technology and market requirements.
Approach
To solve this bottleneck, our R&D team launched a one-year joint development project with the leading Chinese NEV brand. Starting from atomic-level alloy design, we repeatedly adjusted the proportions of nickel, chromium, molybdenum, and other elements while improving the smelting and heat treatment processes. We finally developed a customized special alloy.
Outcome
Three key results were achieved:
Lightweight: 15% lighter than conventional alloys, increasing vehicle range by approximately 8%.
Reliable: Performance degradation remained below 5% after testing at 200℃ and completing one million fatigue cycles, far exceeding industry standards.
Cost-effective: Process optimization and localized production reduced the total cost by 30% compared with imported materials, helping the brand balance high performance with affordability and supporting rapid mass production and market launch.
Hidden Guardian of Cycling Safety: Rebuilding Brake Cable Reliability for a Renowned Brand Challenge
Challenge
For a global leading bicycle brand, brake reliability was make-or-break. Its premium mountain and road bikes suffered from brake cable issues—easy wear/breakage and rust-induced jamming in wet conditions—keeping the after-sales failure rate above 8%. Beyond fostering “poor quality” perceptions, brake failures threatened rider safety: brake-related complaints made up 40% of total after-sales issues, and “brake safety” was the top concern for new customers, dragging down sales.
Approach
To solve this, we launched a “Reliability Upgrade” dedicated R&D with the brand:
Redesigned the steel alloy formula with more wear-resistant, corrosion-proof materials;
Optimized the weaving process to boost fit and force uniformity, reducing local overwear.
Added a nano-scale protective coating to block moisture and rust in harsh conditions (rain, mud, etc.).
Outcome
Results exceeded expectations: The new brake cables’ failure rate plummeted to below 0.5% (near “zero failure”). This not only slashed the brand’s after-sales costs but also eliminated consumers’ safety worries. Post-cooperation, sales of the series rose 25% YoY, and it earned “most reliable brakes” acclaim in the pro cycling community—strengthening the brand’s premium market position.
