With advancements in the premium bicycle market, fully concealed cable routing (also known as full internal routing) has become a prevailing trend. This design not only enhances the bike’s sleek appearance and premium feel but also reduces wind resistance, improves aerodynamic performance (referred to as "aero"), and simplifies cleaning. However, achieving fully concealed routing introduces several technical challenges.

GoodGi’s high-temperature nylon conduit plays a key role in bicycle manufacturing, helping to solve these issues.

Challenges and Issues with Fully Concealed Cable Routing

• High Difficulty in Cable Threading: Whether during factory assembly or later cable replacement, the common magnetic guide method is tedious and time-consuming, posing a significant challenge to production efficiency and cable replacement speed.
• Friction Issues: Cables hidden within the frame increase friction, affecting smoothness and posing potential risks to bicycle performance and lifespan.
• Noise Problems: Vibrations during riding cause cables to shift, generating noise and potentially accelerating wear.

Giant’s Needs and Design Goals

As a globally renowned bicycle manufacturer, Giant Manufacturing (9921.TW) has developed an innovative solution for fully concealed cable routing in its premium GIANT bicycle models. By fixing conduits inside the frame, this approach ensures cable protection and stability, overcoming the shortcomings of traditional magnetic threading methods and making cable routing simpler, faster, and more precise. Design requirements include:

• High-Temperature Resistance: Capable of withstanding 180°C for 50 minutes.
• Balanced Flexibility and Rigidity: Facilitates installation with sufficient firmness for application while retaining flexibility for easy threading.

Solution for Fully Concealed Cable Routing: PA Nylon Conduit

To address these challenges, PA nylon conduit was selected as the optimal solution by GoodGi, effectively meeting the following needs:

• High-Temperature Resistance: PA nylon conduit withstands temperatures up to 180°C, maintaining shape and appearance during a 50-minute oven process without deformation or damage.
• Flexibility: With moderate rigidity, it supports easy installation while remaining flexible for smooth threading.
• Cost-Effectiveness: Compared to other materials, PA nylon is competitively priced, benefiting overall manufacturing costs.

PA nylon conduit uses extrusion technology to ensure quality. Want to learn more? Watch the extrusion process video.

Before settling on PA nylon, other materials were tested with the following results:

1. Fiberglass Sleeving: Often considered for high-temperature needs, it met temperature requirements but lacked flexibility for threading. Attempts to harden it with varnish added complexity to the process.
2. PP Polypropylene Sleeving: Insufficient rigidity and temperature resistance.
3. Teflon Sleeving: Excellent temperature resistance and moderate rigidity, but prohibitively expensive for cost-effective production.

Through the PA nylon conduit solution provided by GoodGi, Giant’s premium bicycles have achieved significant technical optimization in fully concealed cable routing. This innovative design not only resolves challenges in cable installation and protection but also offers inspiration and opportunities for future bicycle manufacturers.

If you’re seeking solutions for bicycle cable protection or are interested in other products, feel free to contact us. GoodGi provides professional technical support and samples.