E-Bike Frame Design
Budget / Salary$250–750
TypeFreelance project
LocationRemote
Posted1 hour ago
I’m after a seasoned mechanical-CAD engineer who can perform FEA and can take my concept of a Pivot-Phoenix-inspired, full-suspension e-bike and turn it into a production-ready aluminum frame that survives sustained 50–60 mph urban runs without bulking up. Above everything, I’m prioritising structural strength and long-term durability, so every tube profile, pivot and weld-ready joint must stand up to ISO 4210 load cases plus real-world motor torque, braking forces and big-hit impacts.
Key parameters you’ll be working with
• Motor: CYC X1 Pro Gen 4 fully integrated inside the main triangle
• Battery: 72 V (20S) pack, 80 × 21700 cells, hidden within the tubing
• Wheel set-up: 29″ front / 27.5″ rear
• Travel targets: ≈ 200 mm front / ≈ 210 mm rear on a single-chain drivetrain
• Intended material: 3D-printed aluminum (SLM) with CNC post-machining for all critical interfaces
• Use case: high-speed urban commuting with occasional trail abuse
What I need from you
1. Optimised suspension kinematics that keep anti-squat, leverage rate and pedal kickback in check across the travel range.
2. Fully detailed 3D CAD model (STEP + native file) sized around the motor and battery envelopes.
3. Manufacturing drawings: orthographic 2D prints with GD&T, tolerances and surface-finish notes tuned for SLM and CNC.
4. Structural & fatigue FEA: include static ISO 4210 tests, dynamic impact loads, motor torque bursts and repeated braking cycles; document safety factors and life expectancy.
5. Design report summarising assumptions, material data, mesh settings and simulation outcomes.
Acceptance criteria
• Frame mass, wall thickness and printed lattice structures balance stiffness with a clean silhouette.
• All pivot hardware is serviceable with common shop tools.
• No single load case produces a safety factor below 1.5; predicted fatigue life ≥ 100,000 cycles at 60 % of peak load.
• Deliverables open flawlessly in SolidWorks 2020 or later.
If this challenge excites you—and you have a portfolio of aluminum bike or moto components to prove it—let’s create a benchmark urban rocket together.
Key parameters you’ll be working with
• Motor: CYC X1 Pro Gen 4 fully integrated inside the main triangle
• Battery: 72 V (20S) pack, 80 × 21700 cells, hidden within the tubing
• Wheel set-up: 29″ front / 27.5″ rear
• Travel targets: ≈ 200 mm front / ≈ 210 mm rear on a single-chain drivetrain
• Intended material: 3D-printed aluminum (SLM) with CNC post-machining for all critical interfaces
• Use case: high-speed urban commuting with occasional trail abuse
What I need from you
1. Optimised suspension kinematics that keep anti-squat, leverage rate and pedal kickback in check across the travel range.
2. Fully detailed 3D CAD model (STEP + native file) sized around the motor and battery envelopes.
3. Manufacturing drawings: orthographic 2D prints with GD&T, tolerances and surface-finish notes tuned for SLM and CNC.
4. Structural & fatigue FEA: include static ISO 4210 tests, dynamic impact loads, motor torque bursts and repeated braking cycles; document safety factors and life expectancy.
5. Design report summarising assumptions, material data, mesh settings and simulation outcomes.
Acceptance criteria
• Frame mass, wall thickness and printed lattice structures balance stiffness with a clean silhouette.
• All pivot hardware is serviceable with common shop tools.
• No single load case produces a safety factor below 1.5; predicted fatigue life ≥ 100,000 cycles at 60 % of peak load.
• Deliverables open flawlessly in SolidWorks 2020 or later.
If this challenge excites you—and you have a portfolio of aluminum bike or moto components to prove it—let’s create a benchmark urban rocket together.
Apply on Freelancer →
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