Scaling Pedal-Powered Logistics
EAV Cargo
EAV Cargo had a working vehicle but not yet a viable one. The engineering needed to be more durable, the costs needed to come down and the production process needed to scale. All three had to move together.
Built in the UK, in six months, from the inside out.
Duration: 6 Months
Stages: Concept to Production in the UK
Basis: In-House Lead Engineer
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EAV was founded during a period of high investor confidence in the micromobility sector.
By the time Matt joined, that confidence had cooled. The COVID bicycle boom had faded, investors were pushing for returns and the business was under real financial pressure.
The brief was clear: make the product commercially viable, fast. The clock was already ticking. -
As lead engineer, Matt was responsible for four things:
Bring the cost of building each vehicle down significantly
Redesign for easier, faster assembly to unblock production
Make the product more durable and reduce the cost of ownership for customers
Deliver additional models to expand the range
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In six months, Matt delivered:
Over £500 off the cost of every vehicle built, with no compromise on quality
A redesigned chassis brought into compliance with draft DIN79010-4
A simplified wiring architecture built for scalable production
Tolerance issues resolved across the chassis and front axle
DFM challenges resolved with suppliers in both the UK and USA
Full delivery of the Cage variant including its entire electrical architecture
An upskilled engineering team and a business-wide milestone process implemented across the organisation
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