Full vehicle programme for an electric delivery two-wheeler: architecture, chassis, swappable battery pack, wire harness, durability validation and certification — plus production planning for ramp to 1,000 units/month.
Vehicle architecture and 3D packaging with ergonomic studies came first, then chassis design and FEA, then prototype builds on welding fixtures. Each of the 6 beta vehicles incorporated lessons from the previous: revised mounting points, improved cable routing, refined battery rails. The second prototype completed a 12,000 km durability programme; findings were fed back into the design before the certification builds. In parallel, the team produced production BOMs and manufacturing drawings for three ramp scenarios (20/100/1,000 units per month) so costing was ready for investor and supplier discussions.
The 3.2 kWh swappable pack went from bench prototype (cells + BMS PCB) through FEA-validated enclosure design to the production pack with moulded cover (see the battery cover die case study). The full vehicle harness was developed with AutoCAD Electrical schematics, 3D routing in Inventor and nailboard drawings for the build shop.
Pack prototype + BMS
Pack CAD — internals
Production swappable pack
Harness 3D routing
Electrical schematic
Bracket FEA
During rapid throttle cutoff, reverse current through the harness triggered the BMS short-circuit protection — intermittent, hard to reproduce, and it killed the vehicle mid-ride. Root cause analysis traced it to inductive kickback at the relays. Fix: TVS diodes at the relay coils. Fault never recurred across the durability programme.
The long-distance programme exposed real-world failure modes that FEA alone wouldn't catch — fastener loosening, routing wear points and bracket fatigue — each fed back into the design before certification builds.
Every part decision had to survive three different manufacturing strategies (20/100/1,000 per month). This forced disciplined make-vs-buy analysis and drawings that worked for both jobshop and scaled suppliers.
6 beta vehicles built and validated · 2 submitted for ICAT roadworthiness certification · AIS-156-compliant 3.2 kWh swappable pack · 12,000 km durability completed · production documentation ready for 1,000 units/month ramp.
