Engineering an E-Bike as a Complete System: From Concept to Production A successful E-bike project depends on how well the frame, cockpit, accessories and electrical components work together. This case study shows how XON helped refine an initial concept, coordinate multiple suppliers and turn a collection of custom parts into a production-ready bicycle. The completed E-bike combines the frame, cockpit, carriers and lighting as one coordinated product. Good Bicycle Development Starts with the Interfaces When a brand brings us a concept drawing, the overall direction may already be clear. The real engineering work begins at the points where one part meets another. Will the cable path remain smooth through the handlebar and frame? Does the computer mount fit the cockpit without interfering with the front light? Are the rack mounting points positioned correctly for the fender and rear light? Can the selected kickstand work with the final frame geometry? These questions often determine whether a promising design can move into production without repeated revisions. For this project, the customer provided a 3D concept, frame geometry and specifications for the main components. XON then reviewed the aluminum frame, carbon fork and related components as one system. We worked with qualified manufacturing partners to refine the engineering details while keeping the original design direction intact. The initial concept established the product direction. Engineering development turned it into a manufacturable design. A Cleaner Cockpit Without Starting from Zero The one-piece handlebar was one of the most important parts of the project. Its internal structure needed enough space for full cable routing, with transitions that would not create excessive friction during installation or steering. The cockpit also needed an integrated solution for the cycle computer and front light. A completely new mount would have added tooling cost and extended the development schedule. Instead, we adapted an existing XON mount to match the new handlebar and its installation points. The result retained the clean appearance the customer wanted while using a proven product platform. This is often the most effective form of customization: develop new parts where necessary and reuse reliable solutions where they already meet the requirement. An existing XON mount was adapted to match the one-piece handlebar and support both the computer and front light. Developing the Frame and Accessories at the Same Time Accessories are often treated as secondary items, but a carrier, fender or light can affect frame clearances, mounting points and cable routing. Waiting for the first complete frame sample before starting these parts can add months to the schedule. Once the frame and fork drawings were confirmed, XON began developing the front and rear carriers, fenders and lighting components in parallel with the frame samples. This allowed the parts to reach the assembly stage at a similar time. When the frame sample arrived, we could immediately verify bolt positions, hardware alignment, tire clearance and the relationship between the rack and fender. The front and rear lights also required electrical coordination. Their voltage, power consumption and connectors had to match the customer’s E-bike motor system, not only the mechanical mounting points. Parallel development does not remove the need for validation. It gives the engineering team the opportunity to identify interface problems earlier, when changes remain manageable. The front and rear carrier, fender and lighting interfaces were developed alongside the frame. Small Engineering Decisions Can Prevent Large Costs The transition from a concept to mass production always involves practical decisions. Welding access, molding consistency, available hardware and tooling cost can all affect the final design. In this project, the customer’s preferred kickstand did not fit the revised frame geometry. Developing a new kickstand mold would have added cost without improving the rider experience. XON designed a dedicated adapter plate instead, allowing the original kickstand to remain in use. We also coordinated the saddle and grip colors across different suppliers. Color matching may seem minor compared with frame engineering, but inconsistent finishes are immediately visible on a completed bicycle. Both examples reflect the same principle: engineering should solve the actual problem without adding unnecessary complexity. Quality Is Built into the Production Process Structural testing to ISO and EN requirements provides an essential baseline, but passing a test does not by itself guarantee consistent production. XON’s quality team checks the complete bill of materials at the manufacturing site. The inspection covers frame dimensions, appearance and component fit, as well as smaller items such as bolts, cable caps and mounting hardware. These details can affect assembly efficiency and the condition of the finished bicycle. Finding a problem early also prevents it from continuing through an entire production batch. When an issue appears after shipment, we coordinate the investigation with the relevant suppliers and use the findings to improve subsequent production. On-site inspection connects the approved engineering specification with the actual production result. From Individual Parts to a Complete Bicycle The finished E-bike remained faithful to the customer’s original direction, but it also incorporated the changes required for reliable manufacturing and assembly. More importantly, the frame, cockpit, carriers, lighting and standard components were developed as parts of the same bicycle. The value of this approach appears at the interfaces: cleaner installation, fewer late-stage changes and a product that feels consistent when it reaches the customer. XON supports bicycle brands through engineering review, supplier coordination, prototype validation and production management. If you are developing a new bicycle, E-bike or integrated component system, contact us to discuss the technical requirements and development plan. The final bicycle reflects both the original design intent and the practical requirements of production.

The XON XBT-27 combines a bike computer mount, a GoPro-compatible adapter and an independent accessory clamp in one modular system. Its three configurations give cyclists greater flexibility when installing a bike computer, light or action camera. A clean bicycle cockpit often needs to accommodate more than just a bike computer. Depending on the rider and bike setup, it may also need to support a front light or action camera without creating unnecessary clutter around the handlebar. The XON XBT-27 was developed as a modular mounting system for these different requirements. Instead of limiting the rider to one fixed arrangement, it combines three components that can be configured according to the equipment, available space and preferred viewing position. Three Components, One Flexible System The XBT-27 system is built around three key components: XBT-26 out-front bike computer mount XBT-PT-GOP GoPro-compatible lower adapter XBT-28 independent accessory clamp Together, these components support three practical installation configurations. Configuration 1: Standard Out-Front Installation In the standard configuration, the bike computer is positioned ahead of the handlebar for a clear and natural viewing angle. The upper interface holds the bike computer, while the XBT-PT-GOP adapter underneath provides a mounting point for a GoPro-compatible action camera or front light. This arrangement keeps both devices aligned in one compact structure and helps reduce clutter around the cockpit. Configuration 2: Reversed Extension Arm For larger bike computers or cockpit layouts with limited clearance, the extension arm can be installed in the opposite orientation. Reversing the arm changes the height and position of the computer, providing additional space between the device and the handlebar or stem. It can also improve visibility depending on the rider’s position and cockpit geometry. This configuration is especially useful when a standard installation causes interference or places the screen too close to another component. Configuration 3: Independent Camera or Light Mount When a bike computer is not required, the XBT-28 can be used as an independent accessory mount. The circular clamp can be installed on a compatible handlebar or seatpost, allowing a GoPro-compatible camera or front light to be positioned separately from the computer mount. This gives riders more freedom to adjust the location and angle of their accessory according to the bicycle setup and intended use. CNC-Machined Aluminum Construction The main components are manufactured from AL6061 aluminum alloy using precision CNC machining. This construction provides the stiffness required to support electronic devices while maintaining a lightweight and refined profile. An anodized finish improves surface durability and gives the components a consistent appearance suitable for modern road, gravel and performance bicycles. Secure Fit Across Three Clamp Diameters The XBT-27 clamp is compatible with Ø25.4 mm, Ø31.8 mm and Ø34.9 mm mounting diameters. Two rubber shims are included. Each shim is designed for either a Ø25.4 mm or Ø31.8 mm handlebar or seatpost. For Ø34.9 mm installations, the clamp can be fitted directly without a rubber shim. Precision-machined grooves inside the clamp engage with the matching profiles on the rubber shims. This interlocking structure keeps the shim securely positioned and helps prevent the mount from rotating after installation. Replaceable Bike Computer Interfaces Different bike computer brands may use similar-looking interfaces, but their dimensions and engagement directions are not always identical. The XBT-27 uses a replaceable computer interface and can be configured for major systems including: Garmin Bryton Mio Wahoo CatEye The required interface should always be confirmed before installation. A Practical Solution for Different Riding Setups The key advantage of the XBT-27 is its adaptability. Riders can use it as a conventional out-front computer mount, combine the computer with a light or camera, change the arm orientation for additional clearance, or install the accessory clamp independently. Rather than requiring a separate mounting solution for every setup, the XBT-27 provides a modular platform that can be adjusted as equipment and riding requirements change. For brands and bicycle manufacturers, XON also provides OEM and ODM support, including customized interfaces, arm lengths, mounting structures, anodized colors and laser-engraved branding. Contact XON for XBT-27 specifications, compatibility information and customization options.

Challenges in Finding the Right Manufacturer Many businesses face significant challenges when searching for a manufacturer, including: Limited Access to Reliable Suppliers  Finding a manufacturer who meets quality, cost, and delivery requirements can be difficult, especially when sourcing internationally. Communication Barriers & Time Zone Differences Working with overseas suppliers often leads to delays and misunderstandings. Quality Assurance Issues Without proper oversight, ensuring that products meet the required specifications can be challenging. Production Flexibility & Lead Time Management Some manufacturers may not be able to accommodate changes in production schedules or customized orders efficiently. Supply Chain Transparency & Stability Ensuring a stable supply chain with clear tracking and accountability is crucial for long-term business success. Our Solution: Connecting You to the Right Manufacturer At XON, we simplify the process of finding the ideal manufacturer by leveraging our extensive network of trusted suppliers. Here’s how we help: Comprehensive Manufacturing Network We have a well-established network of manufacturers across Taiwan, China, and other key markets, ensuring that we can precisely match you with the most suitable partner for your needs. Specialization in Aluminum Component Processing With expertise in aluminum alloy parts, we offer advanced manufacturing solutions tailored to the cycling industry and other sectors requiring precision engineering. End-to-End Product Development & Customization From initial design to final production, we provide comprehensive support, including R&D assistance, prototype development, and engineering improvements. Strict Quality Control & Compliance We enforce rigorous quality control processes to guarantee that every product meets international industry standards and certifications. Seamless Communication & Efficient Coordination Acting as a bridge between you and the manufacturers, we eliminate communication barriers, streamline the procurement process, and ensure timely delivery. Partner with XON for Reliable Manufacturing Solutions Choosing the right manufacturer is essential for ensuring product quality, cost efficiency, and market competitiveness. With our extensive expertise in manufacturing and trade services, XON provides you with the best resources to optimize your supply chain. Whether you need high-precision aluminum components or a reliable OEM/ODM partner, we are here to help you achieve your production goals.

A bike computer provides essential riding information, including speed, distance, navigation and performance data. To use it safely and conveniently, the mount must hold the device securely and position it where the screen is easy to read. At XON, we develop and manufacture precision-machined aluminum bike computer mounts for different computer interfaces, cockpit designs and accessory requirements. Why the Right Bike Computer Mount Matters A properly designed mount helps keep the bike computer stable on uneven roads and reduces unwanted movement during riding. Accurate interface dimensions and secure fastening are especially important because a loose or poorly fitted device may shift or detach. The mounting position also affects visibility. An out-front mount places the computer ahead of the handlebar, allowing the rider to check information without looking too far away from the road. Stem and handlebar-mounted designs may be more suitable for compact cockpits or bicycles with limited installation space. Since bike computer interfaces are not always interchangeable, the computer brand, model and interface direction should be confirmed before choosing a mount. XON offers solutions for major systems, including Garmin, Wahoo and Bryton, using dedicated or replaceable interfaces depending on the design. Key Features of XON Bike Computer Mounts XON bike computer mounts are manufactured from aluminum alloy, offering a practical balance of low weight, structural rigidity and durability. Compared with many plastic designs, aluminum provides a solid structure and a refined appearance suitable for modern performance bicycles. Precision CNC machining allows accurate control of the computer interface, mounting holes and external profile. This helps maintain consistent engagement, reliable installation and stable dimensions across production batches. Different mounting configurations are available to suit various cockpit designs: Out-front mounting Handlebar or stem mounting Integrated cockpit mounting Stem faceplate mounting Mounting below the stem Selected designs can also include a lower interface for accessories such as front lights, action cameras or GoPro-compatible devices. This allows multiple accessories to be organized around the cockpit without requiring separate handlebar mounts. What to Consider When Choosing a Mount Before selecting or developing a bike computer mount, confirm the following: Bike computer brand, model and interface Mounting position and available installation space Handlebar diameter or stem dimensions Required viewing angle and arm length Need for a light or camera attachment Preferred material, finish and anodized color Integrated handlebars and proprietary cockpits may require model-specific mounting structures, so drawings or physical samples may be needed before development. OEM and ODM Bike Computer Mounts In addition to standard products, XON supports OEM and ODM development for bicycle brands and component suppliers. Custom options may include different mounting angles, arm lengths, computer interfaces, accessory mounts, anodized colors, laser-engraved logos and packaging. Production feasibility and lead time are evaluated according to the design, order quantity and level of customization. Whether you need a standard out-front mount or a cockpit-specific design, XON can assist with product evaluation, CNC manufacturing and production planning. Contact XON to discuss your bike computer mount specifications and development requirements.

XON Hidden Top Cap Review: A Sleek Upgrade for Minimalist Cyclists If you’re all about clean lines and functional design, the XON Hidden Top Cap (Model: XHS-19) might just be the subtle upgrade your bike has been waiting for. With its stealthy aesthetic and integrated screw-concealing mechanism, this component isn't just another pretty face—it delivers both style and performance for riders who demand more from every detail. What Is a Hidden Top Cap? Traditionally, the top cap on a bike's headset holds the fork and stem together during setup. Most of these caps have exposed bolts that can disrupt the smooth, aerodynamic look of a high-end build. The XON Hidden Top Cap reimagines this basic component with an ingenious design that conceals the fixing bolt beneath a sleek, anodized aluminum cap. Why It Matters Cyclists who care about performance know that the devil is in the details. Reducing drag, eliminating visual clutter, and using high-quality components are all part of building a ride that feels—and looks—pro. The XHS-19 helps you achieve this with a flush-mounted design and laser-etched branding that gives off a premium feel without screaming for attention. But don’t be fooled by its minimalist look—beneath that elegant shell is a robust fixing system. The bolt is hidden underneath the cap, accessed only when the cover is removed, offering both security and aesthetics. This not only protects the bolt from sweat, water, and dirt but also prevents accidental tampering. Installation Installation is straightforward for anyone familiar with basic bike maintenance. Remove your old top cap, pre-load the headset as usual, and then mount the XON unit. Once tightened, simply snap or screw the outer cap in place to hide the bolt completely. Voilà—your cockpit is now clean, cohesive, and completely dialed. Final Verdict The XON Hidden Top Cap (XHS-19) is the kind of small detail that can elevate your entire build. Whether you're finishing off a custom road bike or refining your gravel rig, this component delivers a professional look and long-term durability. If you're already obsessing over your cable routing and paint scheme, why leave your top cap out of the equation? For riders who believe that "less is more," this hidden gem from XON truly powers your ride—one detail at a time.