Electric Scooter Production Process

The following is a detailed description of the production process of electric scooters, integrated industrial production and key technical links:

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**I. Design and R&D**

1. Requirement analysis and prototype design

– Complete 3D modeling and functional prototype production according to the safety standards (such as EN 17128, UL 2272) of the target market (such as the EU and North America) and user needs (folding function, cruising range, etc.).

– Verify the frame load-bearing capacity (≥100kg) and folding mechanism stability (100,000 cycle test) through load testing.

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**II. Materials and parts processing**

1. Frame and structural parts manufacturing

– The frame is mostly made of lightweight magnesium-aluminum alloy or carbon steel, which is formed by stamping dies. Some high-end models use carbon fiber composite materials to improve strength.

– The folding mechanism adopts precision stamping or CNC processing to ensure the matching accuracy of components such as shafts and locating pins (tolerance ≤0.1mm).

2. Wheel and motor assembly

– The wheels are made of PU material or pneumatic tires and are produced by injection molds; the motor (hub motor or belt drive) must pass torque and heat dissipation tests.

– The battery pack uses 18650 lithium batteries, spot welded into a 2-parallel 7-series configuration (24V/29.4V), and integrated with a balanced charging protection board.

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**Three, production line assembly process**

1. Frame pretreatment and cleaning

– The assembly line is equipped with automated cleaning equipment, which uses cleaning brushes and magnetic adsorption devices to remove dust on the surface of the frame and impurities in the battery slot to ensure the quality of subsequent installation.

2. Key component assembly

– Frame and folding mechanism: Fix the frame with a clamping bracket driven by a hydraulic cylinder, install the folding device (rotating shaft, positioning pin), and test the stability of unfolding/folding.

– Electrical system integration: Connect the motor, controller (including Hall sensor), and battery pack, and encapsulate them in a waterproof aluminum box, with external aviation connectors and charging ports.

– Wheels and brake system: Install front wheel universal wheels (above 4 inches) and rear wheel drive wheels, configure disc brakes or hydraulic brakes, and test the braking distance (≤2 meters).

3. Functional module addition

– Optional intelligent modules (such as GPS positioning, APP control) or seat components (switched by quick release buckles) to enhance product diversity.

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**Fourth, testing and quality inspection**

1. Performance test

– Cruise range and power: Simulate different loads (50-100kg) and road conditions to verify the cruising range (such as lithium battery pack supports 8-12km).

– Safety test: Pass drop test (1.5 meters height), fatigue test (100,000 cycles) and chemical safety test (heavy metal, plasticizer content).

2. Certification and compliance

– Complete CE (EN 17128), UL 2272 (electrical safety) and other certifications according to export market requirements, and provide technical documents and test reports.

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**V. Packaging and Transportation**

1. Finished Product Packaging

– Use shockproof wooden boxes or customized cartons, marked with CE/UL logo, UN number (UN38.3 certification is required for lithium battery transportation) and safety warnings.

2. Logistics Management

– Optimize the folded size (≤1200mm×500mm×300mm) for sea or air transportation; MSDS and dangerous goods packaging certificates are required for dangerous goods transportation.

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**Sixth, Technical Innovation Direction**

– Intelligent Production: Introduce robot welding and AI quality inspection system to improve assembly accuracy and efficiency.

– Environmentally friendly materials: Promote bio-based plastics or recyclable aluminum alloys in compliance with EU REACH regulations.

– Modular design: Support user-defined accessories (such as lighting systems, storage baskets) to extend product life cycle.

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**Summary**

The production process of electric scooters covers the entire chain of **design and development→material processing→assembly testing→packaging and transportation**, with the core being **safety compliance** (such as EN 17128) and **functional innovation** (folding structure, intelligent control). Industrial-grade production lines improve efficiency through technologies such as automated cleaning and precision assembly, while DIY production focuses on low cost and flexibility (such as homemade controllers). For more information about specific equipment or certification details, please refer to relevant patents and standard documents.