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EV Scooter Design Collaboration with an Indian EV Manufacturer

Client Overview

A growing player in the electric vehicle (EV) segment approached us to resolve design and fitment challenges in one of their EV scooter models. The main issue centered around the front headlight area, where the existing structure did not support proper integration. Additionally, interference between the headlight and mudguard on speed breakers posed serious usability concerns.

They approached Voxel 3D Tech for scanning and design services to support product enhancement.

Our Solution

We began by conducting a complete 3D scan of the scooter’s front assembly using our proprietary i-Scan Light technology. The precise scan data helped us deeply understand the dimensional constraints and integration issues.

Based on the scan, we delivered

  • A redesigned front nose component to accommodate the headlight housing
  • An improved structure that maintained aesthetic continuity and provided mechanical support
  • A revised geometry that eliminated the collision issue between the headlight and mudguard when riding over speed breakers
  • Our design-to-fit approach ensured that the client could go directly into prototyping and testing without trial-and-error iterations.

Scope of Work

  • 3D scanning of EV scooter front end
  • Analysis of interference and spatial limitations
  • Design of new front nose part for proper headlight fitment
  • Redesign of affected components to resolve mudguard conflict
  • Delivery of updated CAD files for direct manufacturing

Outcome & Benefits

  • Resolved headlight fitment issue with a redesigned nose part
  • Improved clearance between headlight and mudguard during operation
  • Faster design iteration cycle by eliminating manual measurement and guesswork
  • Enhanced product usability and rider experience
  • Contributed to a more robust and market-ready EV scooter design

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