Electric scooters are often called"compact mini-cars,"offering the freedom to ride with just one vehicle.So,do you know how electric scooters are made?

 I.Design and R&D

 ①Industrial Design:Focus on appearance and ergonomics.

 ②Engineering Design:Structural strength,battery layout,and motor system simulation.

 ③Prototype Development:Use 3D printing or handmade methods to create sample scooters for testing and validation.

 II.Frame and Structural Components Manufacturing

 Material Selection:

 Aluminum alloy(lightweight and commonly used):Produced via die-casting,extrusion,or stamping.

 Steel(low cost):Formed through tube bending and welding.

 Carbon fiber(high-end):Molded into shape.

 Zwheel scooters feature a lightweight design—an aluminum alloy integrated die-cast frame that not only reduces weight but also minimizes welding points.

 Forming Processes:

 Die-casting:Used for complex-shaped parts(e.g.,steering tube,wheel hubs).

 Stamping:Applied to flat components(e.g.,pedal base).

 Extrusion:Aluminum alloy tubes are cut and shaped.

 Welding:Frame assembly using TIG or laser welding.

 Surface Treatment:Painting,anodizing,or electrophoretic coating.

 *In terms of craftsmanship,the Zwheel D3 single-drive model features an adjustable steering tube design,allowing users to modify the height for a more comfortable riding experience.*

 III.Powertrain Manufacturing

 Motor:

 Hub motors are directly assembled into the rear or front wheel.

 Processes include stator winding,magnet assembly,and housing die-casting.

 All Zwheel electric scooters use magnet assembly.They are equipped with brushless DC motors,where high-performance magnets reduce energy loss and improve efficiency.

 Battery Pack:

 Cell Procurement:Lithium-ion cells(e.g.,18650 or 21700).

 Battery Module Assembly:Cells are connected via spot welding or laser welding.

 Battery Management System(BMS):Circuit boards are soldered and integrated with protection circuits.

 Encapsulation:Sealed in aluminum or plastic casing for waterproofing and shock resistance.

 IV.Electronic System Assembly

 Controller(ESC):PCB assembly(SMT process),sealed with potting compound.

 Dashboard:LCD module assembly,housed in injection-molded casing.

 Wiring Harness Processing:Cable cutting,terminal crimping,and waterproof connector installation.

 Sensors:Speed sensors and gyroscopes(for balance scooters)soldered and integrated.

 V.Suspension and Wheel Assembly

 Tires:Rubber injection molding for pneumatic or solid tires.

 Wheel Hubs:Aluminum alloy die-casting or steel stamping.

 Suspension System:Assembly of spring or hydraulic shock absorbers.

 To ensure better safety,Zwheel scooters are equipped with front and rear spring suspension systems and a steering damper.Additionally,they feature oil disc brakes,providing a car-like SUV experience.

 VI.Final Assembly Process

 Frame pre-assembly:Installation of bearings,bolts,and bushings.

 Motor installation:Securing the hub motor and connecting the axle.

 Battery installation:Embedding the battery pack into the frame and securing wiring.

 Electronic system connection:Linking the controller,dashboard,throttle,brake signal lines,etc.

 Accessory installation:Attaching pedals,handlebars,brake cables,and lights.

 Firmware programming:Writing controller software.

 VII.Quality Inspection and Testing

 Electrical safety tests:Insulation resistance,short-circuit protection.

 Functional tests:Throttle response,brake cutoff,lighting system.

 Performance tests:Range,speed,climbing ability.

 Environmental tests:Waterproof rating(IP),vibration,high/low temperature cycling.

 Durability tests:Wheel lifespan,folding mechanism fatigue testing.

 VIII.Packaging and Logistics

 Packaging design:Shockproof materials and compact boxing.

 Labeling:CE/FCC/UL certification labels,user manuals.

 The above outlines the production process of electric scooters.Zwheel electric scooters are available for both dealership and customization.Feel free to inquire if interested.