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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.
Project ID: 40710918
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31 freelancers are bidding on average $494 USD for this job

Hello, As a seasoned mechanical engineer proficient in the use of CAD,-CAM and possess a deep understanding of the principles of structural engineering with over X years of professional experience under my belt, I believe I can enhance your e-bike concept as envisioned. Specifically, my expertise in FEA and 3D modelling aligns perfectly with your project requirements. I guarantee to develop an optimised suspension system with mechanisms that'll effectively manage leverage rate, overall frame torsional and compressional forces while ensuring not to compromise on aesthetic appeal. My previous designs for bike components like saddles and frames have been recognized for their strength, practicality and sleek finish. These are principles I will bring to bear on designing a powerful yet lightweight frame for your e-bike project. With my knowledge of ISO 4210 load cases, torque application, braking forces and big-hit impacts, along with meticulous fatigue testing, my designs are entrenched in safety protocols without sacrificing performance or design. Additionally, my proficiency working with multiple design software including SolidWorks makes me well-suited for delivering the detailed manufacturing drawings you require. My extensive portfolio in producing clean designs balanced with structural integrity makes me convinced that we can create a reliable benchmark urban rocket together. As цnA+C命À for detailed reports summarising simulatio Thanks!
$555 USD in 5 days
7.8
7.8

Hi there, I can take your full-suspension e-bike concept through production-oriented CAD, suspension kinematics and structural/fatigue FEA, with strength and durability as the primary design drivers. I’ll develop the frame around the CYC X1 Pro Gen 4 motor, 72 V battery envelope, 29/27.5 wheel setup and ~200/210 mm travel, while optimising anti-squat, leverage ratio and pedal kickback. I can then validate the design against ISO 4210 load cases, motor torque, braking and impact loads, including fatigue assessment and safety-factor checks. You’ll receive the detailed SolidWorks model, STEP, SLM/CNC-ready drawings with GD&T and tolerances, FEA results, and a concise engineering report covering assumptions, material properties, mesh convergence and fatigue life. I have experience in mechanical design, FEA, engineering calculations and production-oriented CAD, and can iterate the frame to achieve the required stiffness/strength without unnecessary mass. Could you provide the target motor mounting geometry and suspension hardware/shock dimensions so I can confirm the initial packaging and kinematic layout? Best, Arati
$500 USD in 7 days
6.8
6.8

With a passion for engineering and a breadth of experience in various product design projects, I'm thrilled at the prospect of working with you on this unique e-bike frame. The parameters you've set require a meticulous approach to balancing aesthetics, strength, and functionality—areas in which I excel. Throughout my career, I've honed my skills in 3D CAD modeling, simulation, and technical documentation to produce optimized designs that deliver on their intended purpose. I understand the particular demands of bike and moto components, and my portfolio includes a range of aluminium designs that have demonstrated their durability over time. Your vision for an e-bike that is structurally sound even after sustained urban runs at high speeds is certainly challenging. However, my comprehensive approach to FEA and fatigue analysis will ensure we meet your expectations for safety factors and predicted fatigue life. Moreover, as a Verified and Preferred Freelancer proficient in SolidWorks 2020 or later—the software you stipulated—I guarantee that all deliverables will open flawlessly. My commitment extends beyond just delivering on the project's technical aspects—I prioritize communication and collaboration throughout the project to ensure our combined vision produces the urban rocket you're hoping for.
$650 USD in 4 days
6.7
6.7

Hello; We are interested in your E-Bike Frame Design project. We are a professional team of expert architects from all over the world. Our team offers the highest quality and most effective projects with over 14 years of experience and works with a focus on 100% customer satisfaction. When you choose us, you will have a final delivery that exceeds your expectations. We look forward to working with you! Take a look at our past work on our portfolio: https://www.freelancer.com/u/worldarcpart Kind Regards WORLD ARCHITECTURE PARTNERS
$250 USD in 2 days
6.3
6.3

Your "benchmark urban rocket" project is where my passion and expertise in advanced engineering converge. I have an extensive background in 3D modeling, CAD, and Design for Manufacturing that are fundamental for your e-bike frame's evolution from concept to reality. For starters, I've worked on similar projects involving top-tier materials like aluminum, and have a knack for optimizing designs for efficiency, reducing complexity while never compromising durability. My proficiency in Finite Element Analysis (FEA) is an essential asset to this project. I'm well-versed in creating realistic simulations accounting for dynamic impact loads, motor torque bursts, and repeated braking cycles - a crucial requirement, as you seek a frame that can withstand high-speed urban commuting with occasional trail abuse without bulking up. Rest assured, my emphasis here is to exceed mandated standards like ISO 4210 and factor in real-world loads to deliver an outcome that's not just safe but guaranteeing your bike's longevity.
$500 USD in 7 days
5.7
5.7

I am interested in working on your E-Bike Frame Design project and can develop a strong, functional, and manufacturable frame tailored to your specific requirements. I can focus on achieving the right balance between strength, weight, rider comfort, battery placement, and overall aesthetics while ensuring the design is suitable for electric-bike applications. My approach will include detailed 3D CAD modeling, frame geometry development, component integration, and consideration of manufacturing methods and material selection. I can also account for critical areas such as motor and battery mounting, suspension or wheel clearance, cable routing, structural reinforcement, and ease of assembly. The final design can be optimized for durability, practicality, and a clean professional appearance.
$250 USD in 7 days
5.3
5.3

Sustained 50-60 mph urban runs require precise FEA on pivot points and joint profiles, I run this analysis using Solidworks Simulation to confirm ISO 4210 loads and real-world motor torque. I will build your e-bike frame concept using AutoCAD and Solidworks, developing production-ready aluminum tube profiles and weld-ready joints. The result is a strong, durable frame for the CYC X1 Pro Gen 4 motor and 72V battery pack. What is the maximum allowable battery tube diameter? Send the CAD concept files for your Pivot-Phoenix-inspired e-bike. I have a 5.0 rating across 10 reviews on here, and Preferred Freelancer status.
$390 USD in 21 days
3.4
3.4

As an experienced mechanical-CAD engineer with a deep understanding of structural engineering, I'm excited by the challenge your e-bike frame design presents. My skills in 3D modeling, AutoCAD, and CAD/CAM, along with my background in Mechanical Engineering, make me uniquely suited to take your concept and turn it into a production-ready reality. My portfolio showcases extensive work with aluminum bike components and I have used SolidWorks for over half a decade, guaranteeing smooth compatibility with your preferred software version. The combination of my experience and comprehensive skillset facilitates the optimization of suspension kinematics, detailed 3D CAD modeling around motor and battery envelopes, creation of manufacturing drawings, FEA with static & dynamic impact loads and the generation of design reports - all that you've specified.
$500 USD in 3 days
2.5
2.5

Miramar, United States
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