Research & Design of 3D-Printed E-Bike Mid-Drive Motor Shells for Steel Bikes?

[VWV]

Any Research & Design of 3D-Printed E-Bike Mid-Drive Motor Shells for Steel Bikes?

Objective: Develop 3D-printed motor shells for e-bike mid-drive conversions of traditional steel bikes, prioritizing:

• Preservation of Kinematics: Maintain original bike handling, suspension, and ride quality.
• Q-Factor Optimization: Minimize Q-factor changes for optimal rider ergonomics and pedaling efficiency.
• Optimized Rider Experience: Minimize added weight and maintain the "feel" and enjoyment of the original gravel bike.
• Material Considerations: Explore the use of various materials, including carbon fiber, metal, and other suitable options, for 3D-printed motor shells.

 

[Tomblarom]

Can you provide a little more context?? Are you interested to work on that, or are you a science lab, or do you want to make business off it? Very cryptic post.

 

[steve_sordy]

@VWV might be a student with a project to complete. The question will be part of the research that probably hasn't come up with much so far.

By the way: Welcome to the forum @VWV

 

[VWV]

@Tomblarom , I'm looking to convert my steel Caletti CX frame into an e-bike that maintains a traditional bike feel. I'm currently using a CYC Photon kit, but it's making the bike ride more like a scooter. I'm always open to experimentation, and sometimes these projects turn into business ventures.

Thanks, @steve_sordy, for the warm welcome! I am a life-long learner...however its been a long time since grad school.

If there's any commercial products "or" academic projects, I am open to be an early tester

 

[VWV]

Current Build:

• Using off-the-shelf motors and batteries.
• Wheelset, drivetrain, and brakes are still pending.
• This will provide a good baseline for the project.
• However, I anticipate this initial build will have a scooter-like ride similar to most high-end e-bikes.

Future Goals:

• Design a 3D-printed motor shell compatible [with 1-dimensional stiffness layers to preserve rider "feel"] with Shimano E801 motors (preference for Shimano components).
• Potentially integrate an internal hub drivetrain (current build will use SRAM AXS mullet).

Experience:

• Have ridden various high-end e-bikes from brands like Specialized, Trek, Riese & Müller, Stromer, etc. that all feel like scooters over analog bikes
• Riding experience is limited to approximately 30-minute rides at a time.