Enyring : support for e-bikes development with swappable batteries

ENYRING, a subsidiary of Yamaha Motor, is developing an innovative mobility solution. Based on a Battery-as-a-Service approach, it combines e-bikes, battery management infrastructure, battery swapping station, and a mobile app into an integrated ecosystem. The goal is to make urban cycling more practical through smart product design and modular infrastructure.

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The challenge

ENYRING set out to design a fleet of intelligent electric bikes (City, Sport, Longtail and Cargo) built around a removable battery system. The aim was to allow users to easily recharge and swap batteries at dedicated stations in under a minute. The e-bikes were designed to be robust, modular, and well-suited for shared urban use.

The solution

Kickmaker supported ENYRING from the definition of the initial requirements, specifications and architecture to the mass production of three model of bicycles, one battery, and one home charger.

Our teams addressed mechanical, electrical, and software challenges throughout the project. The objective was to develop a robust design that would be easy to assemble and maintain, and adapting key components to ENYRING’s unique technical and business requirements.

Objectives

Development (mechanical, electronical and embedded software) from scratch of 3 three e-bikes models (City/Sport, Longtail, Cargo) and their accessories, a battery and a home charger
Demonstrate the feasibility through Proof of Concept and prototypes
Optimizing design for scalable, reliable industrial production
Manage the whole certification process for bikes, batteries and home charger
Preparing initial production series with detailed technical documentation to organize the design transfer to the manufacturing company
Design software related maintenance and production tools

Benefits

Strategic sourcing: component selection based on reliability, availability, and compliance with European standards
Mechanical design in SolidWorks: frame, protective covers, battery/motor/user interfaces, and accessories
Electronics: development of custom PCBs for the battery and bikes, integrating advanced, secure, and anti-theft features
Embedded software: development of battery and bike systems on RTOS platforms, in accordance with reliability, security, and industrialization requirements
Communication: specification of wired and wireless protocols
Functional prototyping: validation of structural integrity, battery/sensor integration, and riding experience
Design for Manufacturing (DFM): design adapted to a wide range of industrial processes, from plastic injection molding to hydroforming and extrusion
Design for Assembly (DFA): optimization of assembly, cabling, and production workflows
Technical documentation: illustrated assembly guides (SOPs), bills of materials (BOMs), tolerance stack-up analyses, end-of-line testing procedures, and quality control protocols
Production and maintenance software tools: flashing, configuration, diagnostics, and verification

Expertise

Thanks to our expertise in multi-disciplinary and multi-partner project management, in mechanical engineering, electronics and embedded software, in prototyping and preparation for mass production, we enabled ENYRING to:

Structure the entire bike range around a modular, scalable system
Validate key technical functions early on through mock-ups and functional POCs
Launch their initial production runs under controlled, industry-ready conditions
Build the foundation for future local or European manufacturing with market-specific sourcing

”The collaboration with Kickmaker is a true success story. Their team brings a unique combination of advanced engineering expertise, critical thinking, and ambition, supporting my project from product vision through development and industrialization. Combining Kickmaker’s product development expertise with the manufacturer’s mass-production capabilities to deliver the project to the highest standards of quality, rigor, and execution.
Hirotsugu OshiroCEO of Enyring