The next generation of sheet steel formed e-bikes for the daily commute
M. van Hasselt (TU Delft - Industrial Design Engineering)
E.W. Thomassen – Mentor (TU Delft - Product Architecture Design)
J. Trappenburg – Mentor (TU Delft - Product Architecture Design)
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Abstract
The e-bike market is growing rapidly. E-bikes are becoming a viable alternative to the car for the daily commute, mainly because of better batteries and lighter frames. For Mokumono, a small company that produces sheet metal formed bicycles, this is a great opportunity. A sheet steel formed e-bike frame was designed to fit the image and style of Mokumono, while improving the manufacturability of the frame. By changing the construction of the frame, the manufacturing process is streamlined and more appropriate for potential automation. By using laser brazing to bond the shells instead of laser welding, the post-processing costs have been greatly reduced. The brazing takes place at lower temperatures, which reduces the warping in the material and maintains the strength of the material around the joint. This lowers the overall production costs of a frame compared to the frames produced using the current production process. This e-bike is fitted with high-end parts to create a product of high quality, creating an opportunity for Mokumono.