Foldable Bicycle
Re-engineering a bicycle into a compact foldable solution for last mile transport.
A functioning foldable bicycle made with a low-cost folding mechanism with readily available/modifiable components. Built with the goal to make a personal cycle a practical and usable last mile transport option in the crowded metropolitan city of Mumbai by making it usable with the public transport systems. The attempt was to modify an existing cycle without relying on the expensive materials or systems found in commercial folding bikes.
What was the problem?
Last mile transport has been a big problem in the overcrowded city of Mumbai. While a bicycle has the potential to be a good option, its size makes it impossible to carry on buses and trains. Additionally, cycles are far too large to store in the compact apartments of Mumbai.
Commercial folding bicycles were expensive at the time and relied on complex parts.
So, I thought about how my regular cycle could be re-engineered into a foldable and portable version using readily available parts.
How did I solve it?
Worked on modifying the existing frame of the cycle with a simple hinged folding mechanism.
I cut the main frame tube and welded a 180 degree bushing hinge at the centre and angled the pieces of the frame to keep it stable.
To keep it sturdy and easy to open and fold, I designed a locking system using aligned holes through the hinge plates and secured it with a screw and winged nut(tied to the frame). This ensured that when locked, the frame was stable, strong and safe to ride. It also made it easy to open by hand and fold neatly in half.
Once folded, its length was halved making it compact enough to fit under a desk, inside a car boot, in a big closet or onto public transport. The folded bike could also be rolled on its wheels, reducing the need to carry it.
The design avoided expensive materials or complex mechanisms, everything was made from basic parts found locally. This made the cycle foldable without compromising on its functionality, proving that portability could be achieved without a high-cost design.
The prototype
Photos of the prototype in both its forms
How did I make it?
Deconstruction + Understanding Working
I started by studying the structure of an existing cycle frame using scrap parts(picked from a scrap yard) to understand the stress and load points on the frame as well as the working of the rest of the parts.
Mechanism Ideation
Sketches, mockups, rough prototypes were used to explore hinge concepts and locking systems that could be strong yet easy to make and operate.
Fabrication
The frame was cut at an angle and fitted with a steel bushing hinge. Accurate alignment, angling and welding were the most important steps to build a stable and straight cycle. Following this, holes were made in the hinge plates to lock and troubleshooting was done to align the hinges better. Finally, the screw was welded to the plate and the wing nut was attached to the bicycle rod using cord inserted into a hole made in the metal.
Assembly + Testing
The bicycle was reassembled and tested multiple times to check ease of folding and unfolding, rigidity while riding, and overall portability.
Finishing
