EAV Cargo
Transforming a startup’s MVP into a durable, standards-compliant, positive margin, and production-scalable, commercial electric vehicle. Built in the UK.
Duration: 6 Months
Stages: Concept to Production in the UK
Basis: In-House Lead Engineer
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EAV was founded during a time of high investor confidence in the micromobility EV sector.
In the wake of the COVID bicycle boom, the landscape had evolved and investors were seeking rapid returns on their initial investment.
Matt joined the second wave of staff tasked with transitioning EAV through this phase.
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In his role as lead engineer, Matt was responsible for the tactical delivery of four main goals:
Significantly reduce BoM costs
Unblock production capacity bottlenecks through improved DFA (design for assembly)
Improve product durability; reducing customer OpEx
Delivery of additional models
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During his tenure, Matt was able to deliver the following:
> £500 BoM cost reduction with no impact on perceived quality
Chassis redesigned in compliance with draft DIN79010-4
Harnesses simplified, value engineered & moved to a scalable architecture
Tolerance stacks resolved in the chassis & front axle assemblies
Worked with suppliers to rectify DFM (design for manufacture) challenges in both the UK and USA
Oversaw delivery of the Cage variant, including developing the entire electrical architecture
Upskilled the in-house engineering team
Collaboratively developed and implemented a business-wide stage-gate/milestone process

Chassis frame components tolerance stack rectification

Hub tolerance stack rectification and redesign to improve ease of servicability

Portion of the chassis FEA development completed in Altair's SimSolid

Ensuring compatibility with alternative braking systems

UV Exposure testing on the RIM molded front bumper

New harness optimised for scalable production and cost efficiency

Control board reverse engineering, fault diagnosis & redesign

Arduino-powered PCB fatigue cycle testing rig

On-site DFM review & ideation with a Chicago-based screen manufacturer

Engineering build prototype of the EAV Cage model