kargo
The conclusion of my undergraduate degree was dedicated to a year-long thesis project. This project began with an exploration of the lack of versatile micro-mobility solutions for urban residents. I examined the cargo bike market, and found that these bikes are cumbersome and unadaptable. This research led to me to the concept of a truly adaptable cargo bike. The result is an innovative design featuring a telescoping frame mechanism, which allows the carrying capacity to expand and retract based on the user’s needs. Prototypes were fabricated and tested, leading to a finalized design. I communicated this design through visualizations and a scale modelto demonstrate the telescoping mechanism.
Through a process of in-depth research and analysis, I identified an opportunity within the urban micro-mobility market. I discovered a lack of versatile mobility solutions that can both transport and adapt to the needs of an urban resident. Among a variety of transportation methods, cargo bikes appeared as a potentially exciting solution. However, an investigation of its existing market revealed that while many products solved some problems, they lacked overall adaptability - while being very cumbersome and expensive.
I focused on solving the problem of adaptability of cargo bikes, which created the concept of utilizing a telescopic mechanism to enable expansion and retraction. The design focused on a telescoping frame which allows the user to adjust the carrying capacity as needed, including a compact footprint for storage. To achieve a large range of expansion, I designed the frame to have two parallel tubes, which required changing the traditional bike frame geometry to accommodate this mechanism.
Since the telescoping frame is a novel concept in bicycle design, it was crucial to verify its performance under real-world conditions. I built a prototype using plumbing pipes and 3D-printed connectors, incorporating salvaged bicycle components. My testing focused on the telescoping cargo range, overall structural strength, and general viability. Additionally, a steering linkage and basket were designed and tested to ensure they adapted to the moving frame.
Design development was directly informed by insights from user testing. A key decision was to integrate Pinion’s MGU to provide e-assist functionality for the rider. This involved carefully laying out all bicycle hardware and components and designing a housing to conceal them. I created many iterations to refine surfacing strategies. The cargo basket was also developed to ensure it would seamlessly integrate with the telescoping frame mechanism.
Kargo’s design is centered around the telescoping frame, seamlessly integrating modern e-bike components to meet the diverse needs of urban residents. The design enables adaptable use, expanding to accommodate large payloads and retracting to a compact footprint for easy storage and handling. The incorporation of the Pinion MGU system reduces maintenance compared to conventional e-bikes due to its fewer components. The MGU’s gearbox is controlled via shifters on the handlebars, and the unit is securely mounted within the frame, while remaining easily accessible for repairs. Front and rear lights enhance road visibility and rider safety.
The telescoping frame design enables Kargo to expand by 1.5x its original size, providing ample carrying capacity, and compact storage. Unlike existing cargo bikes, which are fixed in their bulky length, Kargo can adjust as needed. The frame is constructed using a variety of aluminum components, including extruded tubing, hydroformed panels, and milled mounts, ensuring structural strength while minimizing weight.
I built a scaled model to demonstrate product proportions and to serve as a proof of concept for the telescoping frame and basket mechanisms. Although design alterations were necessary for fabrication, the model successfully validates the telescoping mechanisms, providing a physical representation of the design.
