Design optimization and manufacturability of an e-scooter handlebar frame

The following thesis aims to explain, almost in a chronological way, the prototypal development of a component for the electrical-scooter LYNX. This activity has been carried out together with TO.TEM, a start-up that present LYNX as its first e-scooter. The start-up goal is to launch on the market this e-scooter, that differs from the already existing ones. Three wheels and the integration of artificial intelligence are some of the most innovative characteristics. The activity starting point has been the LYNX prototype alpha with the focus on a component called upper support. Upper support is a junction element between the main tube, the handlebar, and the smartphone holder. The first part of the thesis has been focused on reporting all the design changes requests, that have been managed and made, in order to satisfy the project specification. A kinematic analysis has been carried out to realize and verify the upper hook: a component that is connected to the rear zone of the upper support and allows the functioning of the e-scooter folding system. The upper support has been subjected to a material definition analysis, necessary to choose the final manufacturing process and material. Instead, the upper hook has been subjected to a static load analysis to simulate the contact with rear hook, placed on the rear e-scooter fender, and to verify the reliability of the folding system. Geometric tolerancing and dimensioning has been used to create engineering drawings for the upper support and upper hook. The functional modeling has been described step by step. The last part of the activity has been the study of the upper support functional gage to control and validate the component at the end of the manufacturing line. A model of the upper support gage fixture has been also created and studied.