Course Overview:

The Design and Fabrication of E-Bikes course is an intensive program that combines theoretical knowledge and hands-on practical skills to enable participants to design and build their own electric bicycles. Over the course of 30 days, participants will learn the fundamental principles of e-bike design, gain proficiency in fabrication techniques, and assemble their own functional e-bike prototype.

Training & Research Module 1: Introduction to E-Bikes

Introduction to electric bicycles and their advantages
Overview of e-bike components and systems
Examination of different e-bike types and their applications
Introduction to relevant regulations and safety standards

Training & Research Module 2: E-Bike Design Fundamentals

Principles of e-bike design and optimization
Frame design considerations: materials, geometries, and structural analysis
Suspension systems and their impact on e-bike performance
Ergonomics and rider comfort factors
Training & Research Module 3: Electric Powertrain and Battery Systems

Understanding electric powertrains: motors, controllers, and sensors
Battery technologies, capacity estimation, and management systems
Selection and integration of electric components into the e-bike design
Power and efficiency optimization techniques
Training & Research Module 4: E-Bike Dynamics and Performance

Bicycle dynamics and stability principles
Weight distribution and balance considerations
Handling characteristics and performance metrics
Designing for stability, maneuverability, and ride comfort

Compulsory Offline Module 1: Fabrication Techniques – Frame and Components

Introduction to fabrication tools and techniques
Frame fabrication: welding, brazing, or bonding
Component fabrication: handlebars, stem, and seatpost
Quality control and inspection in the fabrication process

Compulsory Offline Module 2: Fabrication Techniques – Battery Integration and Wiring

Battery mounting and integration into the frame
Wiring and electrical system setup
Proper insulation and protection measures
Troubleshooting common electrical issues

Compulsory Offline Module 3: Assembly and Integration

Integration of powertrain components: motor, controller, and sensors
Wheel building and tire installation
Drivetrain assembly: gears, chain, and derailleur
Brake and suspension system installation

Compulsory Offline Module 4: Testing and Calibration

Functional testing of electrical and mechanical systems
Calibration of motor, controller, and sensor parameters
Performance testing and data collection
Safety checks and adjustments

Compulsory Offline Module 5: Finishing and Customization

Painting and finishing techniques for the e-bike frame
Customization options: decals, accessories, and lighting
Personalization and branding considerations
Finalizing the aesthetics and visual appeal

Compulsory Offline Module 6: Presentation and Evaluation

Final assembly and inspection
Presentation of the completed e-bike projects
Evaluation and feedback from instructors and peers
Discussion on further improvements and iterations