Ultra Compact Scooter
Ultra Compact Scooter
Embedded Files
Project Specification
Project Specification
16 in folded length
12 lb total weight
200 lb rider target
20 sec fold/unfold time
6061 aluminum construction
Currently in the process of university-supported patent filing for the scooter’s compact folding mechanism and mechanical architecture.
Senior Design Project - Mechanical Engineering
Senior Design Project - Mechanical Engineering
Designed and fabricated a fully functional ultra-compact mechanical scooter focused on solving first/last-mile transportation for students and commuters. The project emphasized compact packaging, manufacturability, structural validation, and rapid mechanical iteration.
Design Evolution
Design Evolution
Phase 1 – Telescoping Concept
Phase 1 – Telescoping Concept
Maximized compactness but lacked ride stability and steering integration
Phase 2 – Folding Architecture
Phase 2 – Folding Architecture
Improved ride usability but remained mechanically bulky
Phase 3 – Final Design
Phase 3 – Final Design
Balanced compactness, manufacturability, and structural stiffness
Final Design Overview
Final Design Overview
Sliding base mechanism for compact storage
Telescoping handle with locking interfaces
Butterfly locking handle system
Designed around manufacturable aluminum tubing
Engineering Analysis
Engineering Analysis
Finite element analysis was conducted on the handle and base assemblies to validate stiffness under rider loading conditions.
Finite element analysis was conducted on the handle and base assemblies to validate stiffness under rider loading conditions.
Handle max deflection: 0.61 mm
Base max deflection: 0.75 mm
Designed to support 200 lb rider load
Validated before fabrication
Manufacturing and Fabrication
Manufacturing and Fabrication
Base Fabrication
Base Fabrication
Machined from 6061 aluminum tubing
Riveted hinge redesign after adhesive failure
Custom 3D printed spacers for alignment
Stem & Folding Mechanism
Stem & Folding Mechanism
Manual lathe and milling operations
Over-center folding linkage
Telescoping guide rail system
Handle Assembly
Handle Assembly
Folding butterfly handle geometry
Steel reinforcement added after testing failures
Engineering Challenges & Iteration
Engineering Challenges & Iteration
Early prototypes exposed several real-world manufacturing and structural issues that required redesigns during fabrication and testing.
Early prototypes exposed several real-world manufacturing and structural issues that required redesigns during fabrication and testing.
Thin-wall aluminum handle geometry failed under load
JB Weld hinge joints sheared during rider testing
Manual machining introduced tolerance stack-up issues
Additional spacers and riveted joints were implemented to improve reliability and fitment
Final Results
Final Results
Final Prototype Results
Final Prototype Results
Folded size: 16 in × 6 in
Weight: 12 lb
Rider capacity: 200 lb target
Fold/unfold time under 20 seconds
Fully functional fabricated prototype completed
Demonstration of Folding and Unfolding
Demonstration of Folding and Unfolding
Demo.mp4Page updated
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