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Bicycles & E-Bikes
Sealing Solutions for Bicycles and E-Bikes –
Less Friction, Longer Service Life
Precisely Sealed from Suspension Forks to E-Drives
The global bicycle and e-bike market is growing at a remarkable pace. Driven by urbanization, sustainability goals, and a booming active lifestyle trend, manufacturers worldwide are under pressure to deliver components that are lighter, more durable, and require less maintenance—while minimizing friction. From cross-country mountain bike tours to daily commutes on e-cargo bikes: every rotation of the wheel, every suspension fork movement, and every pedal stroke depends on components that reliably seal against dirt, moisture, and wear.
Freudenberg Sealing Technologies has been developing precisely these solutions for decades. With deep expertise in tribology, polymer materials, and custom seal development, Freudenberg Sealing Technologies supports bicycle and e-bike manufacturers with advanced sealing systems that enhance ride quality, extend maintenance intervals, and reliably protect critical components under all conditions.
The Challenges of Modern Cycling
Today’s bicycles and e-bikes are used under extreme conditions. Riders navigate through mud, rain, sand, and frost, and expect their components to function just as reliably as they do on a dry summer day. Manufacturers face a complex set of requirements:
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Lightweight construction without compromising sealing reliability
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Low-friction seals for immediate response to terrain irregularities
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Extended maintenance intervals to reduce total cost of ownership
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Reliable protection against contamination—dirt, mud, moisture, and trail debris
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Weather resistance across a wide temperature range
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For e-bikes: additional protection for electric motors, drive electronics, and battery systems
The bicycle and e-bike market in figures
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+10.3% CAGR
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Global e-bike market volume in 2025
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Approx. $54 billion
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Projected annual growth 2026–2035
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$145 billion
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Expected global market size by 2035
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$18 billion
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E-bike market size in Europe in 2025
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90.6 million
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Bicycles & e-bikes in circulation in Germany alone – of which 17.2 million are e-bikes
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Sealing Systems on all Key Components - Bicycles and E-Bikes
Suspension Fork Seal and Dust Seal
The front fork is the area on every bicycle that is subjected to the most stress. The suspension fork seal (main seal) retains the fork oil under dynamic load and ensures consistent, low-friction performance over thousands of strokes. As the first line of defense, the dirt guard seal (also known as a dust seal) works in conjunction with it—it keeps out dirt, sand, and moisture before they can reach the main seal. The result: longer suspension fork life, stable damping performance, and significantly reduced maintenance intervals.
Freudenberg Sealing Technologies offers the complete range of suspension fork sealing systems: from high-performance standard versions for recreational use to professional competition versions for motorsports and racing.
Prowipe® Oil Seal
The Prowipe® oil seal combines oil sealing and dirt repellency in a single, precision-engineered sealing element. Its wiper geometry ensures that dirt and particles are continuously removed from the sliding surface with every stroke, without generating additional friction. This maintains an optimal lubricating film at all times and provides long-term protection for the fork components against abrasive wear.
Rear Shock Absorbers and Shock Seals
Rear shock absorbers on full-suspension mountain bikes and e-bikes are subjected to high alternating loads while operating in very compact installation spaces. These units require sealing elements with high sealing efficiency, low friction across a wide temperature range, and tribologically stable interfaces. Freudenberg Sealing Technologies supplies precisely tailored sealing systems for air and coil-over shocks—optimized for precise damping control even under high-performance conditions.
Cranks and Bottom Brackets
The bottom bracket is at the heart of the drivetrain and transmits high torque loads. It is constantly exposed to water ingress, dirt, and mechanical stress from pedaling forces. The sealing systems for bottom brackets prevent contaminants from entering the bearing chamber, maintain lubricant film integrity, and enable low-friction pedaling over the long term—even after thousands of kilometers in wet and off-road conditions.
Wheel Hubs and Hub Bearings
Hub bearings rotate continuously under environmental influences, which is why contamination protection is essential for bearing service life. Freudenberg Sealing Technologies’ sealing systems for front and rear wheel hubs reliably keep out moisture, mud, and dirt, protect the bearing raceways, and reduce the need for frequent relubrication or premature replacement. This directly contributes to lowering maintenance costs over the entire service life of the bicycle.
Headset
The headset connects the fork and frame and is responsible for precise, responsive steering at any speed and on any terrain. Low-friction components and protective seals prevent dirt from entering the headset bearing assembly, maintain steering geometry, and prevent the rough, imprecise steering feel caused by contaminated or worn bearings.
Seatposts – Mechanical and Dropper
Both mechanical and dropper seatposts are exposed to constant axial movement, trail debris, and moisture. Sealing and guide elements prevent dirt from entering the seatpost mechanism, maintain consistent performance of dropper seatposts, and protect internal hydraulic or air spring chambers from contamination that causes wear.
E-Bikes: More Power Requires More Protection
Electric bicycles present a new dimension of sealing requirements that go far beyond the mechanical challenges of conventional cycling . E-bike manufacturers must ensure the protection of electric motors, battery systems, and electronic drive components while adhering to the strict weight and space constraints of modern bicycle design.
The Right Material for Every Load
The performance of a sealing solution is only as good as its material. Freudenberg Sealing Technologies draws on a comprehensive portfolio of high-performance polymers and elastomers that are precisely tailored to the requirements of bicycle and e-bike applications. Material selection is guided by the company’s in-house tribology expertise: achieving the optimal balance of friction, wear resistance, weight, and compatibility with lubricants and environmental conditions.
PTFE
Key Properties
Lowest coefficient of friction, chemical inertness, wide temperature range (−200 °C to +260 °C)
Typical bicycle / e-bike application
Suspension fork seals, bottom bracket seals, hub seals – wherever ultra-low friction is critical
PA (Polyamide)
Key Properties
High mechanical strength, low weight, good wear resistance, oil-compatible
Typical bicycle / e-bike application
Guide elements, guide rings for dropper seatposts, lightweight seal carriers
PEEK
Key Properties
Exceptional stiffness and heat resistance, outstanding tribological properties
Typical bicycle / e-bike application
Heavy-duty guides on rear shock absorbers, shaft seals for e-bike motors
NBR / HNBR
Key Properties
Very good oil and fuel resistance, good dynamic properties; HNBR additionally heat and ozone resistant
Typical bicycle / e-bike application
Suspension fork oil seals, shock absorber seals, static bottom bracket seals
FKM
Key Properties
Superior chemical resistance, wide operating temperature range, long service life
Typical bicycle / e-bike application
Seals in contact with aggressive lubricants, e-bike battery system seals
FAQ – Frequently Asked Questions
The most important answers for designers, developers, and buyers in the bicycle and e-bike industry:
News & Stories on Recreational Vehicles
Technology & Innovation
FACT Surface Technology for the Environment: An Adhesive Bonding Process Without Wet-Chemicals
Can bonding processes be designed to work without wet-chemicals? Yes. With FACT, Freudenberg Sealing Technologies is establishing a new, cost-efficient, and sustainable manufacturing process.
Technology & Innovation
Not Afraid of Extreme Conditions
Freudenberg Sealing Technologies’ 94 AU30000 sets performance benchmark, gains traction and praise with customers.
Technology & Innovation
Crossing the Divide
Freudenberg Sealing Technologies supports Trek Bicycle’s innovative suspension.
Automotive & Transportation
E-Bikes in the Fast Lane
What is predicted for cars has already come a long way with bicycles: rapid growth in electrification. E-bikes are the latest trend.
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Recreational
Efficiency, reliability, and low emissions. In the recreational market, these are the mega trends reaching across the world. The demands brought on by legislation, along with competitive markets, are driving factors in most countries experiencing these trends.
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Energy Saving Seals—ESS™
Freudenberg Sealing Technologies radial shaft Energy Saving Seals (ESS™), demonstrate significant reduction of power loss in drive assemblies as opposed to standard sealing elements.
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