Urban e-bike
A 250 W torque-sensing mid-drive on a lightweight aluminium frame with an integrated, removable battery and fully internal routing — built to feel like a bicycle, not a scooter.
Configure
The part that carries your dimensions — frame — is made by aluminium extrusion, which needs 25 days of tooling before the first part exists. No amount of freight speed fixes that, so this product ships from a production run.
A pedelec is placed on the market as a finished machine. The EN 15194 evidence covers the assembled bike, and an unassembled one would ship as loose lithium cells. It arrives 85% built: bars, front wheel and pedals are the only steps left.
The part that carries your dimensions — frame — is made by aluminium extrusion, which needs 25 days of tooling before the first part exists. No amount of freight speed fixes that, so this product ships from a production run.
| Frame | Made to order | Aluminium extrusion |
|---|---|---|
| Delivered | Assembled | 55 min of assembly included |
| Rider height | 178 | 150–200 |
|---|---|---|
| Battery capacity | 540 Wh | 360–720 Wh |
| Handlebar rise | 40 mm | 0–90 mm |
| Rack load | 18 kg | 0–27 kg |
| Terrain | 0.2 | 0–1 |
| Trail | 72 mm | target ≥ 55, ≤ 80 |
|---|---|---|
| Wheelbase | 1081 mm | target ≥ 1040, ≤ 1140 |
| Front centre | 631 mm | target ≥ 600 |
| Required fork axle-to-crown | 430 mm | target ≥ 415, ≤ 445 |
| Bottom bracket height | 285 mm | target ≥ 270, ≤ 300 |
| Standover height | 728 mm | |
| System mass | 19.2 kg | target ≤ 23 |
| Frame mass (raw) | 2.7 kg | target ≤ 3.2 |
| Realistic range (km) | 76 | |
| Energy use (Wh/km) | 6.4 | |
| Rack load rating | 18 kg | target ≤ 27 |
| Assist cut-off (km/h) | 25 |
| Upper headset cup (ZS44) | Ø44 H7/g6 | clearance 0.0091–0.0496 mm · needs a secondary operation |
|---|---|---|
| Lower headset cup (ZS56) | Ø56 H7/g6 | clearance 0.0098–0.0581 mm · needs a secondary operation |
| Bottom bracket shell (BSA68) | Ø34.8 H7/f7 | clearance 0.0236–0.0735 mm · needs a secondary operation |
| Seat tube bore | Ø31.6 H7/g6 | clearance 0.0081–0.0487 mm · needs a secondary operation |
| Rear thru-axle dropout | Ø12 H7/g6 | clearance 0.0058–0.034 mm · needs a secondary operation |
Blocked — see findings
- Below the economic run size for this process
Aluminium extrusion carries €1,400 of tooling. We amortise it over the committed run of 500, so a single unit still prices at €2.80 of tooling — but the run has to happen.
→ Run this one on CNC or SLS and keep the tooling for the production batch.
- Upper headset cup (ZS44) needs a secondary operation
H7/g6 at Ø44 mm asks for a tolerance the as-moulded process does not hold. Zero-stack bearing seat: too loose and the steering knocks, too tight and the cup deforms the head tube.
→ Specify reaming or facing after the primary operation, and state it on the drawing.
- Aluminium 6082-T6 turns this into a Faraday cage
A 2.4 GHz antenna inside a closed metal box radiates almost nothing. This is not a range problem to be tuned out afterwards — the enclosure material is the antenna’s environment.
→ Move the antenna to a plastic window in the housing, fit an external antenna with a bulkhead connector, or build the housing in a polymer.
- Made in production runs, not to order
The part that carries your dimensions — frame — is made by aluminium extrusion, which needs 25 days of tooling before the first part exists. No amount of freight speed fixes that, so this product ships from a production run.
→ It ships from the batch lane in about 41 working days.
- Ships assembled — not a choice we make
A pedelec is placed on the market as a finished machine. The EN 15194 evidence covers the assembled bike, and an unassembled one would ship as loose lithium cells. It arrives 85% built: bars, front wheel and pedals are the only steps left.
Cost breakdown, per unit across a run of 1
| Material | €20.86 | |
|---|---|---|
| Process | €2.2 | |
| Components | €860 | 27 |
| Assembly | €2.93 | |
| Tooling, amortised | €2.8 | |
| Scrap allowance | €71.1 | |
| Freight + handling | €11.59 | |
| Import duty | €235.17 | |
| Landed cost | €1206.66 | before margin and VAT |
What is fixed, and what is yours
The parameters above move; the components do not. Every unit uses the same released bill of materials, from the same certified suppliers, because changing the electronics means repeating the certification — expensive, slow, and invisible to you. The freedom is in the geometry, which is the part you actually see and touch.
frame is made for your order by aluminium extrusion. That split is the whole reason this can arrive in 41 working days instead of six weeks.
Bill of materials
| Component | Supplier | Certification | Lead |
|---|---|---|---|
| 250 W mid-drive motor, torque sensing | Bafang M420 (alt: Ananda M100) | EN 15194 component report, RoHS, REACH | 45 d |
| 36 V controller, 15 A, CAN | Bafang (alt: Ananda) | EMC report, RoHS | 40 d |
| Monochrome top-tube display | King-Meter (alt: Bafang DP C010) | IP65, RoHS | 35 d |
| Bottom-bracket torque sensor | Bafang (integrated) | — | 45 d |
| Integrated removable pack, 21700 cells | Samsung SDI INR21700-50E cells (alt: LG M50LT cells) | IEC 62133-2, UN 38.3, EN 50604-1 | 60 d |
| 10S smart BMS with cell balancing | JBD (alt: Daly) | IEC 62133-2 as part of pack | 40 d |
| 36 V 4 A charger, EU plug | Chicony (alt: Mean Well) | EN 62368-1, EMC, CE | 40 d |
| Internal wiring loom, IP67 connectors | Higo | IP67, RoHS | 45 d |
| Rigid alloy fork, 430 mm A-C, 50 mm rake | Neco / A-Fork | EN ISO 4210-6 fork fatigue | 45 d |
| Zero-stack headset ZS44/ZS56, sealed | Neco (alt: FSA) | EN ISO 4210-5 | 30 d |
| BSA68 threaded bottom bracket | Bafang (motor-matched) | — | 45 d |
| Crankset 170 mm, alloy | Prowheel | EN ISO 4210-8 | 30 d |
| Gates CDX belt + sprockets | Gates Carbon Drive | Gates OEM qualification | 50 d |
| Shimano Nexus 5E internal gear hub | Shimano | Shimano OEM spec | 60 d |
| 700c wheelset, 36H, double wall | Alex Rims (alt: Rodi) | EN ISO 4210-7 | 45 d |
| 700×42 tyre, puncture belt, reflective | Schwalbe Marathon E-Plus (alt: CST) | ECE-R75 (E-bike rated) | 40 d |
| Hydraulic disc brakes, 180/160 mm | Shimano MT200 (alt: Tektro HD-E350) | EN 15194 brake test | 50 d |
| Comfort saddle, elastomer rails | Selle Royal | REACH | 40 d |
| Ergonomic locking grips | Velo | REACH, EN 1811 | 30 d |
| Riser bar + adjustable stem | Kalloy | EN ISO 4210-5 | 30 d |
| Seatpost 31.6 × 350 mm | Kalloy | EN ISO 4210-9 | 30 d |
| Integrated rear rack, 27 kg rated | Racktime / Atran | EN ISO 11243 | 40 d |
| Front light, 70 lux, StVZO | Busch + Müller (alt: Spanninga) | StVZO K-mark, EMC | 45 d |
| Rear light integrated in rack | Spanninga | StVZO K-mark | 40 d |
| Alloy mudguard set with stays | SKS | — | 40 d |
| Centre kickstand, e-bike rated | Ursus | — | 35 d |
| Bike carton, EPE protection set | Local printer | FSC | 30 d |
Compliance
This product class triggers 5 regulatory regimes. We are the manufacturer under EU law even though the factory is in China, so the declaration of conformity and the technical file are ours to hold — and to show you.
| Trigger | Legal basis | Standards |
|---|---|---|
| Pedelec (EPAC) | Machinery Regulation (EU) 2023/1230; excluded from 168/2013 as an EPAC up to 250 W / 25 km/h | EN 15194:2017+A1:2023, EN ISO 4210-2 (frame + fork fatigue), EN 15194 Annex D (EMC for EPACs) |
| Lithium-ion pack over 100 Wh | Battery Regulation (EU) 2023/1542; > 100 Wh triggers Class 9 dangerous-goods handling | IEC 62133-2, UN 38.3, EN 50604-1 (light EV batteries) |
| LED light source | Ecodesign (EU) 2019/2020 + Energy Labelling (EU) 2019/2015 for separately sold light sources | IEC 62471 (photobiological safety), EN 62493 |
| Load bearing | General Product Safety Regulation (EU) 2023/988 | EN 12521 / EN 1730 where furniture-adjacent, In-house static + fatigue protocol |
| Radio module | Radio Equipment Directive 2014/53/EU | EN 300 328 (2.4 GHz), EN 301 489, EN 62479 (RF exposure) |