At Mettler Design, we developed a wiring harness system tailored for an advanced electric scooter. The harness is the backbone of any automotive product, ensuring all components are powered, connected, and able to communicate seamlessly. For this project, our goal was to deliver a safe, modular, and high-performance solution that would support the client’s next-generation electric scooters.
By focusing on safety compliance, robust product design, and modularity, we engineered a harness system that not only meets today’s electric scooter market demands but also ensures durability and easy integration across future models.
FROM CONCEPT TO PRODUCT DESIGN
The process began with brainstorming sessions led by our in-house electrical engineering team. During this stage, we sketched out concepts to define the layout and structure of the harness based on the scooter’s performance requirements.
Next, we transitioned into the product design phase, where CAD software transformed these sketches into detailed 3D models. As a result, we were able to optimize the design for serviceability, maintenance, and integration while ensuring that the harness could meet real-world demands.
PROTOTYPING & TESTING FOR SAFETY
Once the digital models were complete, we moved into the prototyping phase. Here, prototypes were manufactured and tested directly on the scooter. This crucial step allowed us to validate functionality, integration, and safety compliance.
Furthermore, by conducting extensive field and durability tests, we refined the design to guarantee long-term reliability under the challenging conditions faced by modern electric scooters. Consequently, the final harness design combined efficiency, robustness, and cutting-edge materials.
MANUFACTURING & PRODUCTION SUPPORT
After testing was finalized, we provided the client with detailed harness drawings and clear assembly instructions to streamline the manufacturing process. In addition, our focus on simplicity reduced assembly time, minimized costs, and improved scalability for mass production.
Ultimately, this project demonstrated how product design, prototyping, and manufacturing expertise can come together to create a high-performance harness system. The result was a safe, modular, and cost-effective solution that positions the client’s electric scooters at the forefront of the market.
