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Personal Project · Structural Design & Fabrication

Electric Scooter

A custom aluminum scooter frame designed from scratch, validated through FEA deformation analysis, and hand-fabricated using oxyacetylene welding.

Type Personal Project
Material Aluminum
Analysis ANSYS FEA
Fabrication Oxyacetylene Welding
Hero photo — finished scooter frame

Replace with your best photo of the welded frame

Why design and build rather than buy?

✏️ Write this section yourself What motivated this project? What were your design targets — geometry, weight, load capacity, riding style? What did you want to prove or learn by building the frame yourself rather than modifying an existing one?

Designer, analyst, and fabricator

✏️ Write this section yourself You handled the full pipeline solo — CAD, structural simulation, and hands-on fabrication. Describe what that meant in practice. Was oxyacetylene welding a new skill for this project? What was the steepest learning curve?

From CAD to welded steel

✏️ Write this section yourself Describe your CAD process and frame geometry decisions. Then walk through the FEA study — what loads did you simulate, what failure modes were you checking, and what did the results tell you? Did the analysis change your design? Finally, describe the welding process and any fabrication challenges.
CAD model / FEA result
In-progress welding photo

Built, tested, and ridden

✏️ Write this section yourself How did the finished frame perform? Did it hold up structurally as the FEA predicted? What would you change in the design or process with hindsight? What did this project teach you about translating simulation into physical reality?
Finished assembled scooter photo
ANSYS FEA Structural Analysis Oxyacetylene Welding Aluminum Fabrication SolidWorks