Enyring : support for e-bikes development with swappable batteries
Enyring, a subsidiary of Yamaha Group, is developing a sustainable and innovative mobility solution centered around e-bikes with interchangeable batteries. The goal: make shared urban cycling more practical by combining smart product design, a mobile app, and modular charging infrastructure.
Project abstract
▪️ The challenge
Enyring set out to design a fleet of intelligent electric bikes (mountain, hybrid, longtail and cargo models) built around a removable battery system. The aim was to allow users to easily recharge and swap batteries at dedicated stations, with e-bikes that are robust, modular, and suitable for shared urban use.
▪️ Solution
Kickmaker supported Enyring from the ideation phase (definition of the solution and overall architecture) through to mass production, including the design of the first prototypes, while integrating mechanical, electronic, embedded software, industrial and logistics challenges.
The focus was placed on opening the design to multiple business models, the modularity of the design, the ease of assembly, and the adaptation of components to Enyring’s specific needs.
▪️ Objectives
We supported Enyring’s teams in:
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Mechanical development of the four models (MTB, City, Longtail, Cargo), as well as a battery and a charger.
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Optimizing design for scalable, reliable industrial production
- The manufacturing and assembly of intermediate validation and pre-certification prototypes.
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Preparing initial production series with detailed technical documentation (SOP)
- Validation (user testing, UX/UI, stress testing and aging tests) and product certification.
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Sourcing components aligned with performance specs and target costs
Technical developments
As a technical partner, Kickmaker played a key role in the mechanical design and production readiness of Enyring’s e-bikes.
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Complete mechanical design using SolidWorks, including chassis, protective covers, battery/motor mount points, user interfaces, and accessories
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Specification of key sub-systems: cell pack, GPS tracker, smart electronic lock.
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Electronic design and associated embedded software (Battery Controller Unit, Vehicle Controller Unit).
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Design for Manufacturing (DFM) studies: part count reduction, material choices suitable for industrial processes (plastic injection, machined aluminum, welded tubing)
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Development of functional prototypes to validate structural integrity, battery positioning, sensor integration, and user comfort
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Design for Assembly (DFA): optimized assembly process, use of quick fasteners, and simplified production line workflows
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Strategic sourcing: all components selected for reliability, availability, and compliance with EU standards
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Technical documentation (SOP): illustrated assembly guides, part lists (BOM), end-of-line testing procedures, and quality control protocols
- Unit and integration test plans to validate the functional performance of the products.
Key achievements
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:
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Structure the entire bike range around a modular, scalable system
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Validate key technical functions early on through mock-ups and functional POCs
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Launch their initial production runs under controlled, industry-ready conditions
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Build the foundation for future local or European manufacturing with market-specific sourcing
Discover Kickmaker’s expertise
Innovation.
01. Strategy
for design and industrialization.
Define your product development possibilities and the right manufacturing setup to match.
Manufacturing.
02. Product Design
and industrialization.
From POC to mass production, with turnkey industrialization or targeted support at specific stages.
Anticipation.
03. Product lifecycle
management.
Production monitoring, quality control, and in-series product lifecycle tracking.