Our project focused on developing a consumer-friendly e-bike conversion kit. We used engineering principles, design standards, and Oregon’s e-bike classification requirements under ORS 801.258 to guide the system configuration. For the primary controller, we used an Arduino ESP32 board that connects through Bluetooth to a cadence sensor, which measures pedaling RPM and sends a signal to control motor assistance. During prototyping and development, we used CAD modeling software and 3D printing to support rapid, reliable, and budget-friendly production. This process allowed us to test fit components, improve the design, and reduce manufacturing complexity. Overall, we created a modular e-bike conversion kit that is easier to install, maintain, and modify for future design improvements.
