Engineering Stories: FLIT-16 production is underway!

Oct 11, 2019

After an incredible end to our Kickstarter campaign, we are very excited to let you know that manufacture is underway! We worked really hard with our manufacturing partner in Taiwan to make sure that everything was geared up for production, so that we could kick things off as soon as our campaign finished.

CNC hinge part
A very shiny CNC-ed hinge part!


The FLIT-16, as you may already know, was designed and built around our custom lithium ion battery pack, which has enabled us to fully integrate the electrical system into the frame. As our battery is custom-built for the FLIT-16, we had to make our own moulds in order to manufacture the parts that make the battery pack unique.

We have finished the tooling now and have started trialling our first few runs of injection moulding!

Flit ebike - first parts of manufacturing tooling
First trial shot with the injection moulding tooling for the battery parts!

We’re pretty pleased with how the first injection moulding trial run went. On the left, the clear parts are the connector housing for the battery. On the right, the top row is the head caps for the battery, these contain the charging port (see the port on the far right head cap). The middle row is the end caps for the battery, and the bottom row is the battery management system (BMS) holder. 


More exciting news: most of the CNC parts of the bike are now complete and they look absolutely fantastic! 

If you’re wondering what CNC parts are, they are metal parts made using a CNC mill to remove material from a metal block until the desired shape and size is achieved – you can read more about CNC milling in our blog post from Dave’s previous visit to Taiwan here.

In a few days we will be able to start welding the front assembly while we wait for the last few parts.


FLIT-16 with CNC parts labelled


Dave, our Technical Lead, is off to Taiwan soon to supervise the very first FLIT-16s being made by our manufacturing partner!

In previous rounds of prototyping, we already completed mechanical testing according to the ISO standards. We are currently manufacturing a small batch of production FLIT-16s which will undergo a new round of even more rigorous mechanical frame testing that goes beyond the required safety standards. We want to push the frames to their limit for added confidence before they hit the road.

One of these FLIT-16s will be coming back with Dave from Taiwan (painted in Blaze Orange!).

Dave measuring hinge parts
Dave checking measurements of the stainless steel hinge inserts during his last visit to Taichung.

Our next blog post will be directly from our manufacturing partner (including photos of the ebike in Blaze Orange) – so make sure you keep a look out for that.

If you haven’t already, don’t forget to subscribe to our newsletter so that we can update you on our manufacturing progress. 

Also, if you have any manufacture related questions from this post, please feel free to ask! Dave is happy to answer any specific queries.

Check back here or follow our Facebook,Instagram, or Twitter accounts to find out more!

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