E-bikes and two-wheelers

Plastic materials for e-bikes, e-motorcycles, and battery-swap and charging equipment

Row 1 Body panels and covers
- GRN-PCAS-W510Flame-retardant weather-resistant PC/ASA
Row 2 Battery case (Li-ion pack)
- GRN-PC-N510Halogen-free flame-retardant PC
Row 3 Battery compartment / under-seat bin (in contact with battery)
- GRN-PP-N510Halogen-free flame-retardant PP
Row 5 Controller box, electrical box
- GRN-PCA-N510Halogen-free flame-retardant PC/ABS
Row 6 Lamp housing
- GRN-PCA-N510Halogen-free flame-retardant PC/ABS
Row 7 Lamp lens
- GRN-PC-L110Transparent PC
Row 8 Dashboard housing, display cover
Row 9 Mudguards
- GRN-PP-N510Halogen-free flame-retardant PP
Row 10 Seat base, rear-rack plastic parts
- GRN-PP-E510Flame-retardant glass-fiber-reinforced PP
Row 11 Connectors, charging socket
- GRN-PA66-E510Halogen-free flame-retardant glass-fiber-reinforced PA66
Row 12 Motor cover, hub-motor end-cap parts
- GRN-PA6-E510Flame-retardant glass-fiber-reinforced PA6 (GFRPA)

Pain points and material advice

New standard: body parts must be flame retardant too
Pain point
Body covers used to be made mostly of non-flame-retardant ABS, PP or ASA. The new national standard requires V-1 for these parts, and V-0 for electrical parts and parts in contact with the battery. Flame-retardant compounding affects toughness, appearance and weather resistance.
Advice
First classify each part under the new national standard: electrical parts, battery-contact parts, other parts. Then test the flammability rating at the actual wall thickness. For appearance parts, test flammability, low-temperature impact and color difference after xenon-arc weathering together.
Candidates
Plastic limit: less plastic, lower weight
Pain point
Total plastic mass must not exceed 5.5 % of the vehicle mass, with the battery pack housing counted. Vehicle designs must reduce the number of plastic parts or their wall thickness.
Advice
Use stiffer materials to thin the walls, for example glass-fiber-reinforced PP instead of standard PP. Use high-flow flame-retardant PC or PC/ABS for battery housings, with a thin-wall design. Validate impact and stiffness before reducing material.
Candidates
Battery and charging safety
Pain point
Most electric bicycle fires are related to batteries and charging. Battery housings, charger housings and battery swap cabinets must all be flame retardant and must not produce flaming drips.
Advice
Battery housings should reach V-0 to GB 43854-2024 and be validated for drop and crush. Charger housings must also consider glow-wire requirements. Use high-CTI flame-retardant reinforced materials for connectors and charging sockets.
Candidates
Outdoor use: UV, humidity and cold
Pain point
Vehicles and battery swap cabinets face sun and rain for years. Housings fade and become brittle, and crack more easily in falls in winter.
Advice
Test impact and color difference of appearance parts after xenon-arc weathering. Set the low-temperature impact temperature by region of use. For appearance parts of new-national-standard models, choose a flame-retardant weather-resistant formulation.
Candidates
Shared vehicles: durability and repair cost
Pain point
Shared two-wheelers are used heavily and often knocked and dropped. Battery compartments are plugged and unplugged repeatedly.
Advice
Use high-toughness grades for covers and battery compartments, and run life tests on snap fits and plug-in points. Color matching at the compounding stage reduces painting, and scratches do not expose a different base color.
Candidates

Plastic parts for e-bikes, e-motorcycles, shared two-wheelers, batteries, chargers and battery-swap cabinets: body panels, battery cases, charger housings, controller boxes, lamp housings and lenses, dashboards, mudguards, seat bases, connectors and motor covers.

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Materials in the electric two-wheeler

Example grade / typical values — to be corrected by GREENPOLYMER Typical values. Refer to the actual TDS.

GRN-PCAS-W510

Flame-retardant weather-resistant PC/ASA

Tensile strengthISO 527-1/-2

48–58 MPa
Weathering (color difference)ISO 4892-2 · Xenon-arc 1000 h; design target

ΔE ≤ 3
Flammability ratingGB/T 5169.16 / UL 94 · 1.5 mm; design target, subject to test report

V-1
Used for
- Body panels and covers
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Features
Weather-resistant, flame-retardant
Typical values
Charpy notched impact strengthISO 179-1/1eA · 23 °C

15–35 kJ/m²
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

85–100 °C
DensityISO 1183

1.18–1.25 g/cm³
Processing
Drying
80–85 °C, 2–4 h
Melt temperature
230–260 °C
Mold temperature
50–80 °C
Why this material
Large appearance surfaces; outdoor sun exposure; V-1 required by the new national standard
GRN-PC-N510

Halogen-free flame-retardant PC

Tensile strengthISO 527-1/-2

60–68 MPa
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

V-0
Charpy notched impact strengthISO 179-1/1eA · 23 °C

20–50 kJ/m²
Used for
- Battery case (Li-ion pack)
- Charger housing
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Features
Drop-resistant, halogen-free, heat-resistant
Typical values
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

115–128 °C
DensityISO 1183

1.20–1.24 g/cm³
Processing
Drying
120 °C, 3–4 h; moisture content ≤ 0.02 % recommended
Melt temperature
280–310 °C; for flame-retardant grades keep within the TDS upper limit
Mold temperature
80–110 °C
Why this material
Battery case (Li-ion pack)Both the new national standard and the battery standard require V-0; removable batteries must survive drops
Charger housingHigh-voltage circuits inside, generating heat; indoor and outdoor use
GRN-PP-N510

Halogen-free flame-retardant PP

Tensile strengthISO 527-1/-2

20–28 MPa
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

V-0
Charpy notched impact strengthISO 179-1/1eA · 23 °C

3–6 kJ/m²
Used for
- Battery compartment / under-seat bin (in contact with battery)
- Mudguards
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Features
Halogen-free flame-retardant, low density, low cost
Typical values
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

55–65 °C
DensityISO 1183

1.00–1.10 g/cm³
Processing
Drying
Usually not needed; if damp, 80 °C, 1–2 h
Melt temperature
190–220 °C (not too high for flame-retardant grades)
Mold temperature
30–60 °C
Why this material
Battery compartment / under-seat bin (in contact with battery)The new national standard requires V-0 for parts in direct contact with the battery
MudguardsLarge parts; impact resistance; resistant to mud, water and UV; V-1 required by the new national standard
GRN-PCA-N510

Halogen-free flame-retardant PC/ABS

Tensile strengthISO 527-1/-2

55–65 MPa
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

V-0
Charpy notched impact strengthISO 179-1/1eA · 23 °C

10–30 kJ/m²
Used for
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Features
Halogen-free, heat-resistant, dimensionally stable
Typical values
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

80–95 °C
DensityISO 1183

1.17–1.20 g/cm³
Processing
Drying
100–110 °C, 3–4 h
Melt temperature
250–280 °C
Mold temperature
60–90 °C
Why this material
Controller box, electrical boxElectrical part, V-0 required by the new national standard; needs heat dissipation and water protection
Lamp housingClose to LEDs and circuits, generating heat; outdoor
Dashboard housing, display coverElectrical part; the cover lens must transmit light and resist scratches
Battery-swap cabinet doors and linersOutdoor; several batteries charging inside, so flame retardancy is needed
GRN-PC-L110

Transparent PC

Tensile strengthISO 527-1/-2

60–68 MPa
Light transmittanceISO 13468-1 · 3 mm; design target

≥ 88 %
Charpy notched impact strengthISO 179-1/1eA · 23 °C

60–80 kJ/m²
Used for
- Lamp lens
- Dashboard housing, display cover
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Features
Light-transmitting, impact-resistant
Typical values
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

125–135 °C
DensityISO 1183

1.19–1.21 g/cm³
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

HB
Processing
Drying
120 °C, 3–4 h; moisture content ≤ 0.02 % recommended
Melt temperature
280–310 °C; for flame-retardant grades keep within the TDS upper limit
Mold temperature
80–110 °C
Why this material
Lamp lensLight transmission; impact resistance; UV resistance
Dashboard housing, display coverElectrical part; the cover lens must transmit light and resist scratches
GRN-PC-L120

IR-transmissive black PC

Tensile strengthISO 527-1/-2

60–68 MPa
Charpy notched impact strengthISO 179-1/1eA · 23 °C

60–80 kJ/m²
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

125–135 °C
Used for
- Dashboard housing, display cover
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Features
Black, IR-transmissive
Typical values
DensityISO 1183

1.19–1.21 g/cm³
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

HB
Processing
Drying
120 °C, 3–4 h; moisture content ≤ 0.02 % recommended
Melt temperature
280–310 °C; for flame-retardant grades keep within the TDS upper limit
Mold temperature
80–110 °C
Why this material
Electrical part; the cover lens must transmit light and resist scratches
GRN-PP-E510

Flame-retardant glass-fiber-reinforced PP

Tensile strengthISO 527-1/-2

50–70 MPa
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

V-0
Flexural modulusISO 178

4–6 GPa
Used for
- Seat base, rear-rack plastic parts
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Features
Load-bearing, stiff, dimensionally stable
Typical values
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

120–145 °C
Charpy notched impact strengthISO 179-1/1eA · 23 °C

5–9 kJ/m²
DensityISO 1183

1.15–1.30 g/cm³
Processing
Drying
Usually not needed; if damp, 80 °C, 1–2 h
Melt temperature
190–220 °C (not too high for flame-retardant grades)
Mold temperature
30–60 °C
Why this material
Load bearing; dimensional stability; cost
GRN-PA66-E510

Halogen-free flame-retardant glass-fiber-reinforced PA66

Tensile strengthISO 527-1/-2 · dry

140–170 MPa
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

V-0
Flexural modulusISO 178

8–10 GPa
Used for
- Connectors, charging socket
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Features
Heat-resistant, halogen-free flame-retardant, dimensionally accurate
Typical values
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

230–250 °C
Charpy notched impact strengthISO 179-1/1eA · 23 °C; dry

8–12 kJ/m²
DensityISO 1183

1.45–1.55 g/cm³
Processing
Drying
80 °C, 4–6 h (desiccant dryer); moisture content 0.05–0.2 % recommended
Melt temperature
280–300 °C; do not exceed the TDS upper limit for flame-retardant grades
Mold temperature
80–110 °C
Why this material
High-current plugging and unplugging; damp outdoor conditions; V-0 for electrical parts
GRN-PA6-E510

Flame-retardant glass-fiber-reinforced PA6 (GFRPA)

Tensile strengthISO 527-1/-2 · dry

130–160 MPa
Flammability ratingUL 94 · 1.5 mm; design target, subject to test report

V-0
Flexural modulusISO 178

8–10 GPa
Used for
- Motor cover, hub-motor end-cap parts
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Features
Flame-retardant, heat-resistant, stiff
Typical values
Heat deflection temperatureISO 75-1/-2 · 1.80 MPa

190–205 °C
Charpy notched impact strengthISO 179-1/1eA · 23 °C; dry

8–12 kJ/m²
DensityISO 1183

1.40–1.50 g/cm³
Processing
Drying
80 °C, 4–6 h (desiccant dryer); moisture content 0.05–0.2 % recommended
Melt temperature
260–290 °C
Mold temperature
80–100 °C; upper end for a better surface
Why this material
Close to the motor and coils; vibration; road impacts

Industry overview and trends

Output keeps growing
In 2025, China produced about 54.9 million electric bicycles, up about 29 % on the previous year. From January to November 2025, industry revenue and profit grew about 21 % and 42 % respectively.
The new national standard is fully in force
The new Safety Technical Specification for Electric Bicycles (GB 17761-2024) has applied since 2025-09-01. It sets stricter requirements on fire resistance and flame retardancy, plastic content, tamper resistance and braking of the whole vehicle. In 2025, more than 12.5 million electric bicycles were traded in for new ones, speeding up the replacement of old bikes with compliant new ones.
Two provisions matter most for plastic parts
First, non-metallic materials must be flame retardant: electrical circuits and connected electrical parts, and parts in direct contact with the battery pack, must reach V-0, while trim, mudguards and other non-metallic parts must reach V-1 (to GB/T 5169.16; wires, tires and some others excepted). Second, total plastic mass must not exceed 5.5 % of the vehicle mass, with the battery pack housing included. This means body plastic parts must be both flame retardant and reduced, and some covers will switch to metal or thinner walls.
Battery safety is regulated separately
Lithium-ion batteries for electric bicycles have their own mandatory national standard (GB 43854-2024, in force since 2024-11-01). Non-metallic battery pack housings must reach V-0, and printed boards V-1.
Smart features and exports
About 20 % of e-bikes are now smart, with more electronics in displays, control units and lights. Export models must also meet target-market requirements, such as EN 15194 for electrically power-assisted cycles in the EU; the Batteries Regulation, Regulation (EU) 2023/1542, which is in force and requires LMT batteries to be replaceable by an independent professional from 2027-02-18; and UL 2849 and UL 2271, which are common in the US.

China produced about 54.9 million e-bikes in 2025 (about +29 %).
The new e-bike safety standard GB 17761-2024 has applied since 2025-09-01. More than 12.5 million e-bikes were traded in for new ones in 2025.
Two rules matter most for plastics: flame retardancy and the 5.5 % cap on plastic mass. Non-metallic parts in electrical circuits and parts in direct contact with the battery pack must reach V-0; other non-metallic parts such as trim and mudguards must reach V-1 (GB/T 5169.16).
Lithium-ion batteries for e-bikes follow GB 43854-2024 (in force 2024-11-01): non-metallic battery enclosures V-0, printed boards V-1.
About 20 % of e-bikes are now "smart". Export models must meet target-market rules such as EN 15194, Regulation (EU) 2023/1542 (LMT batteries replaceable by an independent professional from 2027-02-18), UL 2849 and UL 2271.

Part-to-material guide

Full list · 13 parts

This table shows common industry practice for first-round selection. The final choice depends on the applicable standards, the OEM's material specification and validation results (to be verified by GREENPOLYMER).

Body panels and covers

Flame-retardant PC/ABS, flame-retardant PP, weather-resistant ASA / PC/ASA (motorcycles and export models), ABS (older models)

Why: Large appearance surfaces; outdoor sun exposure; V-1 required by the new national standard
Key requirements: V-1 (new national standard); UV resistance and color difference; low-temperature impact; weight reduction
Common standards: GB 17761-2024; GB/T 5169.16; ISO 4892-2
GREENPOLYMER grade: GRN-PCAS-W510 (flame-retardant weather-resistant PC/ASA, V-1 design target); GRN-PCA-N510 (V-0); GRN-PP-N510 (V-0). When flame retardancy is not required: GRN-PCAS-W310, GRN-ASA-W110, GRN-PCA-W310