Sourcing & Materials Selection

Motor: Brushless DC (BLDC) Hub Motor

• Material: The motor casing is typically made of aluminum alloy, which is lightweight, corrosion-resistant, and good at dissipating heat.
• The hub motor is mounted directly inside the wheel. This 500W motor generates enough power to propel the bike to speeds of 40 km/h.A BLDC motor is highly efficient, has fewer moving parts, and provides good torque, essential for balancing speed and hill climbing. Aluminum helps reduce the overall weight of the bike and avoids overheating during extended use.

Battery: Lithium-ion Battery (36V, 15Ah)

• Material: The casing is typically made of plastic or aluminum alloy for protection. Inside, lithium-ion cells are used due to their high energy density.
• The lithium-ion battery provides the necessary power to drive the motor. It stores 540 Wh of energy, providing a range of up to 50 km per charge.Lithium-ion batteries are chosen for their excellent energy-to-weight ratio, long lifespan, and fast charging capabilities. They provide sufficient power for the 50 km range while keeping the bike lightweight and compact.

Controller: Brushless Motor Controller (36V/48V, 20A)

• Material: Plastic housing with aluminum heat sinks to dissipate heat generated by power electronics.
• The controller manages the power flow from the battery to the motor, allowing for smooth acceleration and speed control.The controller is designed to handle the power requirements of the 500W motor efficiently. It ensures smooth operation and protection against overvoltage or overheating. Aluminum heat sinks prevent damage due to heat buildup.

Throttle: Half-Twist Throttle with LED Display

• Material: The throttle casing is made of plastic with a rubber grip for comfort.
• This component allows the rider to control the speed of the bike by twisting the throttle, much like a motorcycle. The LED display shows battery status and speed.Plastic and rubber materials are lightweight and durable, providing ergonomic control while minimizing weight. The LED display ensures easy monitoring of battery charge and speed in real-time.

Pedal Assist Sensor (PAS)

• Material: Small plastic sensor encased in rubber for protection.
• The PAS system detects when the rider is pedaling and automatically provides electric assistance from the motor.The PAS system allows for increased range by integrating the rider's pedaling effort with motor assistance. It’s a lightweight component with minimal energy consumption.

Frame: Aluminum Alloy Bicycle Frame

• Material: Aluminum alloy (typically 6061 or 7005).
• The frame is the main structure of the bike, supporting the rider and all components. It is designed for use with 26-28 inch wheels.Aluminum alloy is lightweight yet strong enough to support a load of 90 kg. It is corrosion-resistant, which extends the lifespan of the bike, and offers a good balance between durability and cost compared to carbon fiber or steel. The lightness of the frame also contributes to higher speeds and longer range.

Wheels and Tires: 26-inch Wheels with Tubeless Tires

• Material: Aluminum alloy rims with rubber tires.
• The wheels and tires support the weight of the bike and rider, provide traction, and contribute to overall speed and range.Aluminum rims are lightweight and durable, providing a good compromise between strength and performance. Tubeless tires are chosen for their better resistance to punctures and lower rolling resistance, which improves range.

Brakes: Mechanical or Hydraulic Disc Brakes (160-180mm Rotors)

• Material: The rotors are made of stainless steel, and the calipers are typically made from aluminum alloy.
• Disc brakes provide the necessary stopping power, especially when traveling at higher speeds of 40 km/h.Disc brakes offer superior stopping power compared to rim brakes, which is essential for an e-bike that can travel at speeds up to 40 km/h. Stainless steel provides corrosion resistance, while aluminum calipers reduce weight.

Suspension Fork: Front Suspension (80-100mm Travel)

• Material: Aluminum stanchions with steel springs or air suspension.
• The suspension fork provides a smoother ride, especially over rough terrain or bumpy roads.The aluminum construction keeps the weight down while providing enough strength to absorb impacts. A suspension fork improves rider comfort without adding significant weight.

Lights: LED Front and Rear Lights

• Material: Plastic casing with LED bulbs.
• LED lights are highly energy-efficient, drawing minimal power from the battery. Plastic casing is lightweight and durable, keeping the overall bike weight low.LED lights improve visibility for night riding or poor weather conditions.

Handlebars and Seat

• Material: Aluminum handlebars with foam or gel seat.
• The handlebars allow for steering, while the seat provides comfort for the rider.Aluminum is lightweight and strong, providing reliable steering control. The seat uses gel or foam padding to ensure comfort during long rides, especially important for maintaining endurance over a 50 km range.

Fenders: Plastic Fenders

• Material: Plastic.
• Plastic is lightweight and resistant to rust, making it ideal for fenders, which need to be durable and able to withstand exposure to the elements.Fenders protect the rider from mud, water, and debris.

Kickstand: Adjustable Aluminum Kickstand

• Material: Aluminum alloy.
• The kickstand allows the bike to stand upright when not in use.Aluminum is lightweight yet strong, making it a perfect material for a component that needs to support the bike’s weight without adding unnecessary mass.