Vibe - One Wheel E-BikeFabrication
Overview
Fabrication Overview
The following methods of manufacturing are used to fabricate the parts that Vibe is built with along with suggestions to source these services (not sponsored):
| Manufacturing Method | Description / Tools Used | Sourcing Options |
|---|---|---|
| Steel Tube Bending | 1 inch tube with 3" CLR bending die | Local metal fabrication or tubing shops. From my research, custom car muffler fabrication shops have reasonable prices for this service. |
| MIG Welding | For frame joints and structural assembly | Welding and fabrication services |
| Sheet Metal Cutting/Bending | Used for control box enclosure | SendCutSend |
| 3D Printing | For electronics enclosures | Local makerspaces or 3D printing bureaus |
Parametric CAD Design
The mechanical design of the Vibe was digitally produced in Fusion 360 CAD software, (see fusion file in downloadables). To help build a scalable design that is easily customizable for different sizes of dropout distances/axle sizes and/or seat heights, the modelling in Fusion was done with parametric design in mind. Here are some of the available parameters that can be edited to produce frames of different sizes:
To access/modify these parameters, look under (Design Workspace) -> Solid -> Modify -> Change Parameters
| Section | Parameter Name | Value | Unit | Comments |
|---|---|---|---|---|
| Hub Motor / Axle | HubMotorDiameter | 12.00 | in | — |
| RimDiameter | 18.00 | in | — | |
| AxleLength | 11.22 | in | — | |
| AxleProtrusion | 1.614 | in | Distance from flange face to end of axle = Axle Protrusion | |
| HubMotorWidth | 4.252 | in | — | |
| AxleDiameter | 18.00 | mm | M18 Size Axle | |
| DropoutDistance | 8.68 | in | Center-to-center of dropouts (see wheel axle terminology diagram) | |
| AxleFlange | 6.00 | mm | — | |
| WasherThickness | 2.70 | mm | Washer thickness for the axle (stack multiple to adjust dropout distance) | |
| Frame Tubing | FrameLargePipeOD | 1.05 | in | Outer Diameter of the tube used in the frame |
| FrameLargePipeWall | 0.113 | in | Wall thickness of the tube used in the frame | |
| BendRadius | 3.00 | in | Tube bend radius die | |
| CopingDistance | 0.30 | in | Tube coping distance | |
| Dropout | DropoutSheetMetal | 0.375 | in | SendCutSend – Mild Steel |
| Other Fabrication / Fit | SlideFitTolerance | 0.031 | in | Tolerance for slide fit |
| ResinPrintingWallThickness | 1.00 | mm | Wall thickness for resin 3D-printed parts |