Ultra Compact Scooter

• Urban commuters and students face a persistent first/last-mile transportation gap

• Existing scooters are bulky, difficult to store indoors, and inconvenient to carry

• The goal was to create a fully mechanical, ultra compact scooter that could be carried and stored like a personal item

• Folded size comparable to a water bottle (12 × 5 × 5 in)

• Total mass under 15 lb

• Rider load capacity up to 200 lb

• Intuitive, tool free folding with no loose parts

• Simple mechanical architecture with no electrical systems

• Triple-folding mechanical architecture

• Sliding base mechanism for compact storage

• Telescoping handle with locking interfaces

• Designed for aluminum extrusion and machined components

Finite element analysis was conducted on the handle structure to evaluate deflection and stress under a 100 lb load applied at the grips.

Results:

• Maximum deflection < 1 mm

• Stress within acceptable limits for aluminum structure

• Confirmed sufficient stiffness for rider control

• Validated handle geometry without needing additional reinforcement, reducing weight and part complexity

Structural simulation was performed on the scooter base to evaluate deflection and stress under 200 lb rider weight  during rider loading and transport conditions.

Results:

• Maximum deflection ≈ 0.05 mm

• Load distributed effectively through folding structure

• No critical stress concentrations detected

• Confirmed base structure met stiffness targets while maintaining compact packaging

Unfolded Drawing

Folded Drawing

• Created fully dimensioned fabrication drawings for both folded and unfolded configurations

• Documented overall envelope dimensions to validate compact storage targets

• Produced multiview orthographic layouts with standard title blocks and scale references

• Defined critical hinge and sliding interface geometry for mechanical alignment

• Followed standard mechanical drafting conventions for clarity and manufacturing readiness

• Accepted increased mechanical complexity to achieve extreme compactness

• Prioritized folded footprint over ride comfort and wheel size, accepting reduced rolling efficiency in exchange for portability.

• Selected aluminum tubing and machined joints to balance strength and weight

• Designed locking mechanisms to avoid loose parts during folding