After a small commission to modify an existing electric bicycle, Ryuger Bicycles asked if we could design and build a custom all-carbon fibre electric bike. This would be the first bike we have ever made (or designed) but with enthusiasm from the client, we set about the task. The design of the bike was based on images supplied by the client which set the scene for the type, size, and look of what was to be Ryuger’s first electric bike.

 A statement in advanced composites, the bike needed to be light, strong, and convey the look and feel of a quality product. The project started as a series of 3D computer models of customer-supplied parts (wheels, motor, front forks) and from there we ‘filled in the blanks’. Ensuring we stayed true to the client’s vision regular communication and transfer of CAD images ensured all design decisions were discussed.

 Both Rhino and Solidworks played an integral role in the design, component build methodology, CNC machining operations, and full-part manifest. With storage areas, USB phone charging, adjustable seating, adjustable handlebar, and grip positions, comprehensive motor parameter control, and feedback, the bike is truly unique.

 Operationally it handled well and was a comfortable ride, the bike also exhibited a range of over 150km off a single charge while bringing a smile to anyone’s face who rode it.