Final Project Documentation

Reginald Itiseng - Fab Academy 2025

Project Presentation Video

A 1-minute introduction to the Electric Scooter project.

Introduction

My Final Project

This section introduces my final project idea and begins the documentation process.
I will update this page as I make progress throughout the Fab Academy course. Below is a brief description of my proposed final project.

Electric Scooter

The Electric Scooter project aims to design and build a compact, efficient, and eco-friendly personal transportation device. The scooter will feature a lightweight frame, a brushless DC motor, and a rechargeable battery system to provide reliable urban mobility. Key features include electronic speed control, regenerative braking, and a digital dashboard for real-time speed and battery monitoring. The design will focus on safety, portability, and ease of use, making it suitable for short commutes and campus travel. By integrating smart electronics and robust mechanical components, this project demonstrates practical skills in digital fabrication, embedded systems, and sustainable design.

Below is a concept sketch of the Electric Scooter.
This illustration will be updated as the project develops.

Electric Scooter Concept

Background Research - Who's done what beforehand?

Before starting my final project, I conducted extensive research to understand existing solutions, technologies, and design principles related to electric scooters. This background research helped me identify gaps in the market and opportunities for innovation.

Click on the images to view the sources.

Jay Dhariwal's final project
Jay Dhariwal's final project
Bicycle converted to an electric bike.
Ivan Gonzalez's electric scooter (FabAcademy 2020)
Ivan Gonzalez's electric scooter (FabAcademy 2020)
Reclaiming an old broken electronic scooter
Final Project: Building a Derp-e-bike! Posted on December 16, 2022 by Maxwell Yun
Electric bike conversion
Final Project: Building a Derp-e-bike! Posted on December 16, 2022 by Maxwell Yun
electric cart
Electric go cart (Fab Academy 2019)
Hakan Zayin's electric go cart final project
self balancing electric skateboard
TARIGOPPULA SAI ADITYA VYNATHEYA(Fab Academy 2018)
Self balancing Electric scateboard.

Jay Dhariwal's Final Project (2019): Jay was motivated by the urgent need for electric vehicles in India, aiming to reduce carbon emissions and dependence on imported oil. His project focused on documenting the design and fabrication of a low-cost, easy-to-build electric vehicle by converting a standard bicycle into an electric bike, with plans to add solar power and a sun-shade for thermal comfort. Jay’s approach included using a modular design, starting with an e-bike conversion kit and solar system, and then developing custom components such as a motor controller PCB and smartphone integration for sensor data. He highlighted the use of spiral development, the importance of hands-on learning in electronics and fabrication, and the potential for extending the project to more advanced electric vehicles or adding features like air quality sensing and autonomous driving.

Ivan Gonzalez's Electric Scooter (2020): Ivan reclaimed and rebuilt a broken commercial electric scooter, emphasizing repair and sustainability. He detailed the process of diagnosing faults, replacing damaged electronics, and designing custom PCBs for improved control. Ivan’s documentation shows the importance of reverse engineering, iterative prototyping, and using open-source tools for both hardware and software.

Maxwell Yun's Derp-e-bike (2022): Maxwell’s project used 10S lithium-polymer batteries from two Turnigy packs connected in series. He selected an off-the-shelf Flipsky VESC 6 as the motor controller and a T-Motor P80 II KV100 outrunner motor, originally designed for agricultural quadcopters. This motor provides high torque at low RPM, but requires a reduction drive to power the rear wheel. Maxwell’s documentation highlights practical choices in battery, controller, and motor selection, and the importance of adapting components for new applications.

Hakan Zayin's Electric Go Cart (2019): Hakan's project began with several ideas, including an electric longboard and an arcade machine, but he ultimately chose to build a fully electric go-kart with unique features. Instead of traditional mechanical steering, he implemented an electronic tank-like steering system using a potentiometer, where turning the wheel adjusts the speed of each motor for directional control. The frame was designed in Fusion 360 and made from lightweight plywood, reinforced with jute and epoxy after testing alternatives to carbon fiber for strength and cost-effectiveness. Hakan used CNC milling for fabrication and designed custom pedals with a flex sensor for throttle control, protected in a 3D-printed flexible PLA case. He also integrated an RFID-based authentication system and a display for user feedback, connecting multiple boards via I2C. This project demonstrates the value of iterative prototyping, combining digital fabrication, embedded electronics, and creative problem-solving to achieve a robust, innovative electric vehicle.

TARIGOPPULA SAI ADITYA VYNATHEYA's Self-Balancing Electric Skateboard (2018): This project aimed to create a self-balancing skateboard, i assumed as I read that it will be using using the MPU6050 gyroscope and accelerometer sensor, along with PID control for balancing and maybe a flywheel or some clever motor controll. Although the project appears to have never been fully completed, the design and approach—especially the use of real-time sensor data and control algorithms for stability—were particularly interesting to me and inspired my own ideas for implementing balance and control in personal electric vehicles.

Concept & Design - What I designed.

coming soon..

Sources and Inspirations - The sources I used.

Sources

Inspirations

Xiaomi M365 Electric Scooter
Xiaomi M365

Popular commercial electric scooter known for its minimalist design and portability.

Segway Ninebot Scooter
Segway Ninebot

Reference for dashboard integration and safety features.

DIY Electric Scooter
DIY Community Builds

Various open-source and maker projects for custom scooter fabrication.

Materials and Components - Materials, cost and source.

Materials - Bill of Materials

Qty Description Price Link

Parts and Systems Fabricated - What parts and systems were made?

coming soon..

Processes Used - What processes were used?

coming soon..

Questions and Challenges - What worked? What didn’t?

coming soon..

Evaluation - How was it evaluated?

coming soon..

Implications and Reflection - What are the implications?

Implications of the Electric Scooter Project

The development of my electric scooter project demonstrates the potential for sustainable, accessible, and locally manufactured personal transportation. By designing and fabricating the scooter structure myself, I was able to tailor the frame for lightweight portability and urban use. The use of BLDC motors, paired with a commercial controller, allowed for efficient power delivery and reliable performance.

A key implication of this project is its contribution to sustainable transport solutions. Electric scooters offer a clean alternative to fossil-fuel vehicles for short commutes, helping to reduce urban congestion and air pollution. By documenting the fabrication process and sharing design files, I hope to encourage local manufacturing and empower others to build or adapt similar vehicles using accessible digital fabrication tools.

Reflections and Future Improvements

Building a custom interface to control the BLDC motor controller was both challenging and rewarding. It provided hands-on experience with embedded systems and user interface design. In future iterations, I would focus on improving the integration between the controller and the dashboard, possibly adding wireless connectivity for remote monitoring and diagnostics. I would also explore optimizing the frame design for even greater durability and ease of assembly.

One significant area for improvement is implementing regenerative braking, which I have not yet achieved. Adding this feature in the future could further increase energy efficiency. Additionally, as I gain more experience in electronics design, I plan to build my own BLDC motor controller to replace the commercial unit, allowing for deeper customization and learning. Developing a more advanced battery management system (BMS) would also enhance safety and extend the scooter's lifespan.

Opportunities for Replication and Collaboration

All design files, code, and documentation are openly shared to enable others to replicate, modify, or build upon this project. The modular approach to the scooter's electronics and structure makes it adaptable for different needs or environments. I encourage others to experiment with alternative materials, motor types, or control interfaces, and to contribute improvements back to the community. Through collaboration and open-source sharing, projects like this can accelerate the adoption of sustainable transport and digital fabrication skills worldwide.

Appendix

Download Project Files

All files are provided under a Creative Commons Attribution Non Commercial license.

Acknowledgements - Who helped?

I would like to acknowledge the Fab Academy for providing this incredible opportunity to learn and grow in digital fabrication.
Special thanks to my sponsors for their generous support throughout this journey.
I am also deeply grateful to my instructor for their guidance, encouragement, and expertise.