Structure
Establish a parametric CAD architecture across the major motorcycle subsystems.
CAD · MANUFACTURING · VEHICLE INTEGRATION
WARWICK MOTO
Electric motorcycle development across MotoStudent competition and the Isle of Man TT Zero concept programme.
PROJECT OVERVIEW
Developing electric racing motorcycles from concept to delivery.
My work within Warwick Moto spanned the design, manufacture and integration of electric racing motorcycles across both MotoStudent and the Isle of Man TT Zero concept programmes.
As Manufacturing and CAD Lead, I helped establish a structured, parametric CAD architecture that supported rapid iteration, subsystem ownership and complete vehicle integration.
The work combined mechanical design, reverse engineering, manufacturing development, battery integration and cross-functional collaboration across a multidisciplinary engineering team.
ENGINEERING APPROACH
Building the vehicle as an integrated system.
Design
Develop components around packaging, structural and manufacturing requirements.
Integrate
Coordinate frame, powertrain, battery and mechanical systems within the complete vehicle.
Deliver
Manufacture, assemble and validate the motorcycle within a compressed competition timeframe.
MOTO STUDENT VIII
Inaugural MotoStudent Motorcycle
Delivering Warwick's first MotoStudent motorcycle required a scalable engineering workflow capable of supporting parallel subsystem development while maintaining control of the complete vehicle.
01
MULTIDISCIPLINARY CAD
Parametric Vehicle Architecture
A structured CAD architecture was established across seven distinct subsystems to create a more robust and scalable vehicle-development process.
- Led the motorcycle CAD programme from concept through delivery.
- Structured the motorcycle into seven controlled subsystems.
- Enabled rapid iteration while maintaining design intent.
- Improved subsystem ownership across the wider team.
- Supported complete vehicle integration through a shared CAD structure.
PROGRAMME DELIVERY
A complete operational motorcycle delivered within ten months.
02
VEHICLE INTEGRATION
Frame & Powertrain
The frame and powertrain assemblies were developed alongside each other to ensure mechanical compatibility and efficient use of the available packaging envelope.
- Integrated structural and propulsion systems within the motorcycle package.
- Managed interfaces between independently developed subsystems.
- Considered mounting, access and serviceability during CAD development.
- Supported physical manufacture and final vehicle assembly.
03
BATTERY INTEGRATION
Bespoke Battery Pack
A bespoke battery pack and mounting system was designed, manufactured and validated within a four-month development window.
FINAL VEHICLE
MotoStudent VIII
The completed motorcycle became the only UK entry in the MotoStudent VIII competition.
ISLE OF MAN TT ZERO
Electric Concept Motorcycle
My later work with Warwick Moto focused more heavily on mechanical component design, reverse engineering and detailed system development for the electric racing superbike concept.
04
MECHANICAL DESIGN
Component Development
Mechanical components were designed and developed to support the wider electric motorcycle programme, with a focus on performance, packaging and reliability.
- Designed mechanical components for the electric racing superbike.
- Applied reverse-engineering methods to existing fork geometry.
- Developed a secure charging-port locking mechanism.
- Researched brake-system architectures suitable for the vehicle.
- Supported wider mechanical system development and integration.
05
REVERSE ENGINEERING
Fork Development
Existing fork geometry was reverse engineered to create a usable CAD representation for the wider motorcycle assembly.
- Measured and reconstructed existing component geometry.
- Created manufacturable CAD models from physical components.
- Defined interfaces required for integration with the motorcycle.
- Improved understanding of design intent through reverse engineering.
06
MECHANISM DESIGN
Charging Port
A dedicated locking mechanism was developed for the motorcycle's charging port to provide a secure and practical interface.
- Developed the charging-port cover and locking arrangement.
- Considered packaging within the motorcycle bodywork.
- Refined geometry for usability and secure engagement.
- Produced detailed CAD renders for design review.
07
TECHNICAL CAD EXERCISE
Gearbox Casing
A separate technical exercise explored gearbox casing design and internal component packaging through detailed CAD and rendering.
08
DESIGN FOR MANUFACTURE
Battery Casing Modules
The battery casing was developed around modular internal structures, allowing the pack geometry to be divided into components that were more practical to manufacture and assemble.
- Developed modular internal battery-casing structures.
- Considered manufacturing feasibility from the outset.
- Integrated individual cell-support features within the package.
- Balanced packaging density with practical assembly requirements.
PROJECT REFLECTION
Engineering beyond individual components.
Warwick Moto developed my ability to work across complete vehicle systems rather than treating components in isolation.
The projects strengthened my experience in CAD, reverse engineering, manufacturing and multidisciplinary collaboration while requiring design decisions to be communicated clearly across a large team.