The build started with simple materials — cardboard mockups, 3D-printed components, and plywood panels — to quickly establish the scooter’s proportions and overall ergonomics. These early prototypes let me test handlebar height, deck length, and wheel placement before committing to metal. Each iteration revealed something new that would drastically change the design, causing for a complete rework of the frame and body.  With a fixed and tight budget, I needed to guarantee that the final metal fabricated parts would fit perfectly, thus explains the tedious and time consuming prototyping phase that took up a majority of the 3 month design and build process.

Originally, to save costs, the neck of the scooter was to be made of 3D printed nylon, then wrapped in fiberglass to increase strength. However, this approach soon failed as it was almost impossible to achieve good dimensional accuracy and structural integrity. I then opted to make the design out of sheet metal, which required a complete redesign to make the parts manufacturable. 

Power was supplied by an 850 W motor paired with a 24 V motor controller salvaged from an old Segway, giving the scooter excellent acceleration and a smooth, controlled ride. On a single charge, it could comfortably cruise at ~20 mph for over an hour.

The frame and structural components were fabricated from 14-gauge stainless steel sheet metal. While this provided excellent rigidity, the design proved to be heavier than desired and required re-engineering to optimize the balance between strength and weight.

The images to the right and below highlight the neck folding mechanism—one of the most challenging mechanical design elements. The neck needed to lock securely in two positions:

1. Riding position

2. Storage position

This was achieved with a 3/8" pivot bolt and stainless steel quick-release pins that could be locked or removed quickly.

Also visible in the top-right image is the neck bearing assembly, which is set at a ~7° angle to ensure perfect front-to-rear wheel alignment in the Y-axis. Two clamped bearings secure the assembly, allowing for precise, adjustable steering.