Confidentiality note: The customer name is withheld under a commercial confidentiality agreement. Project details and figures are based on information supplied by Dongying Chiheng Brake Materials Co., Ltd.
Customer Background
The customer is a leading Chinese new-energy logistics-vehicle manufacturer producing more than 50,000 vehicles annually. Its electric light truck combines battery-related curb weight with complex coordination between regenerative and friction braking.
The Challenge
The existing rear brake shoes reportedly required replacement after approximately 20,000 km. The customer needed better wear resistance and thermal stability for frequent urban stop-start operation.
- Extend service life.
- Maintain stable friction as regenerative contribution changes.
- Reduce material and manufacturing cost.
- Support OEM validation and a national service network.
Material Development
Using a 4.5-ton full-load mass and the motor regeneration strategy curve, Chiheng developed a high-temperature resin formulation reinforced with ceramic fiber.
Bench testing
After 2,000 braking cycles, the supplied record reports 0.8 mm wear, compared with 1.5 mm for the former product.
Fleet validation
Ten pilot vehicles in urban distribution and cold-chain transport accumulated 150,000 km. Average brake-shoe life reportedly reached 55,000 km, a 120% improvement.
Industrialization and Cost
Backing-plate stamping optimization increased material utilization from 68% to 82%, supporting an 8% unit-cost reduction. Formal supply approval followed in Q4 2024.
Service Support
Training and diagnostic support covered more than 200 service stations. A direct spare-parts channel reduced reported response time from 72 hours to 24 hours.
Results
- Initial annual order reportedly reached 80,000 sets across three models.
- Average life reached 55,000 km in the pilot program.
- Unit cost reduced by 8%.
- Estimated annual purchasing savings reached RMB 2 million.
- End-user approval reportedly increased to 92%.
- A joint next-generation development agreement was established.
Capabilities Demonstrated
Application-specific formulation, durability testing, regenerative-braking coordination support, stamping optimization, OEM industrialization and service-network response.
