Sustainable Design of a Wooden Electric Scooter Using Autodesk Fusion

Abstract

This thesis investigates the design, simulation, and optimization of a do-it-yourself (DIY) electric scooter frame crafted from bamboo—a renewable, low-cost, and widely available material—using basic hand tools and minimal technical infrastructure. The project challenges conventional manufacturing paradigms by proposing an open-source, modular design that prioritizes accessibility, sustainability, and community-driven innovation. Structural simulations in Autodesk Fusion 360 validated the frame’s mechanical integrity under an 800 N vertical load, revealing a maximum von Mises stress of 51.25 MPa (27% below the bamboo composite’s yield strength), a displacement of 0.632 mm, and a minimum factor of safety of 4.039. Topology optimization reduced material usage by 40%, enhancing the scooter’s lightweight and eco-efficient profile. The design emphasizes modularity, ease of repair, and adaptability to regional material variations, enabling decentralized production in resource-constrained settings. While the study is limited to static simulations and lacks physical prototyping, it demonstrates that high-performance, low-carbon mobility solutions can be democratized through computational tools and grassroots engineering. By integrating sustainable materials with open-source principles, this work provides a replicable framework for equitable urban transportation—proving that industrial infrastructure is not a prerequisite for innovation. Sustainability and mobility can emerge from local ingenuity and collaborative design.