E-Bike Frame Design
USD 250–750
About the project
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.
Skills required
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