From the granulate to a mudguard

Beitrag vom:2. September 2022

The perfect product in 8 steps

Have you ever wondered how a mudguard is made? Well thought-out developments and state-of-the-art technology are necessary to produce the perfect product. Join us step by step through the production process of the MUDROCKER! We promise you: It’s pretty exciting.

Man riding his bicycle through a puddle in the forest

Step 1: It begins with an idea

What is the current trend? What new bicycle geometries are there? Our product managers continuously keep an eye on the bike industry. After a comprehensive market analysis, the product idea is finally created. In addition to the user-friendliness and safety of the product, it is important that all components can be produced economically and in top quality. 

Mudguard from SKS displayed on a computer

Step 2: The baby takes shape

All project participants from the product management, development, design and toolmaking departments work “in-house” and are optimally networked with each other. The development department is in action first: The mudguard is initially constructed in 3D format on the computer and a prototype is created on the 3D printer based on the data.  

Mudguard prototype with different components

Step 3: Test, test, test

Our team is very bike-friendly. The prototype is therefore thoroughly tested by SKS colleagues in field trials. Our “water spraying machine” also offers meaningful insights: Equipped with the prototypes, the bike rolls on a wet belt conveyor to simulate a ride in the rain. Now we will analyse exactly what protection the prototype offers.

Mudguards on a bicycle being tested on a machine

Step 4: Tailor-made design

Of course, a mudguard should not only be practical, but also look good. Therefore, our designers now start to give the technical construction an attractive, modern look. Another prototype with the final design is created and will be checked in detail by our experts. When everything is perfect, the injection moulds are constructed using the 3D process.

A drawing of a mudguard

Step 5: Precision work is called for now

The injection moulds are now built in our own in-house toolmaking department with an accuracy to a hundredth of a millimetre. The mould consists of two halves, namely the nozzle side and the ejector side. Every day, 15 tool mechanics work on new tools. Some 2000 injection moulds have already been produced at SKS for the production of bicycle accessories.

One half of an injection moulding tool

Step 6: Recyclable raw material 

The plastic granulate is stored, for example, in large silos on the SKS site. We use thermoplastic plastics that can be melted and reformed. Mechanical crushing allows the plastic to be recycled completely in an energy-efficient manner. The recycled granulate can then be used as a raw material for the production of new products.

Black injection moulding material (plastic granulate)

Step 7: Under pressure

From the silo, the granulate passes through a pipe system to one of the 75 injection moulding machines. Just like in a meat mincer, the plastic is now turned, heated and homogenised by an auger. Under pressure, the hot plastic mass is injected into the previously installed injection mould, where it hardens and then is ejected out of the hollow mould as a finished mudguard.

Mudguard is taken out of the injection moulding machine by suction cup

Step 8: Off out into the world

After the quality check, the MUDROCKERs are packed and ready to be shipped around the world. Maybe you will soon discover a mudguard from SKS GERMANY at a bicycle dealer. Then you will now know with how much care it was created – and that its long-lasting quality contributes to conserving resources and therefore protecting the environment. Made in Germany – made with love!

Salamander sitting on a SKS mudguard