Tuleap is an innovative start-up based in Spain and German developing the world’s first bio-electric scooter that is set to revolutionize micro-mobility, especially in urban areas. By merging innovation with design, the company redefine comapct and physically active mobility solutions that look damn cool.
| Company | Tuleap.es |
|---|---|
| Location | Barcelona, Spain and Frankfurt, Germany |
| Industry | Urban Micro-Mobility |
| Product | The First Bio-Electric Scooter |
| Services | SLS 3D printing (SLS), Stereolithography (SLA), CNC machining, SLM printing, rubber printing, sheet metal prototyping |
| Part Types | Handlebar, rear light, BCM housing, bracket, spring tube, etc. |
| Part Material | AL6061, AL5052, SS304, TPU, Clear ABS-like Resin, Nylon PA12 |
| Lead Time | 18 days – 13 different types of parts, seven manufacturing processes, low quantities of 1-5 parts each. |
Tuleap is an innovative startup based in Barcelona, Spain, and Frankfurt, Germany, on a mission to develop the first bio-electric scooter that utilizes a combination of kinematics and body motion to contribute to a healthier and greener future for urban micro-mobility. After spending several years refining the kinematics concept of the vehicle, Tuleap secured €7.3 millions in funds and was ready to swiftly transition towards serial production, aiming to be the first to market.
Having previously used HLH Rapid’s services during his time as Chief Engineer at General Motors, Frank Lindner, Head of Product Development at Tuleap, shared, “this was the point where we, out of our list, looked for suppliers who could provide serial representative quality, and HLH was for sure one of them.” After carefully considering their options, the Tuleap team chose HLH for the bio-electric scooter project—the next big innovation in urban mobility.
With this bio-electric scooter, everything is new, and there were very few carry-over components that Tuleap could use. The product required working with a wide variety of materials from metals and plastics to transparent and rubber parts came with a lot of technical challenges, and as Tuleap shifted from concept investigation to prototype creation, they leaned on HLH Rapid for its manufacturing expertise. Equally important is “maintaining a compact design and upholding high desirability to align with the preferences of urban markets,” said Dr. Tassilo Gilbert, Managing Director of Tuleap.
Tuleap’s initial plan was to split the handlebar and stem into 4 or 5 different pieces, craft each one through machining, create specific jigs and fixtures, weld all the components together, and finally, grind it before applying a powder coat to meet stringent finishing standards. Developing these components alone was looking challenging.
After reviewing the CAD designs, HLH Rapid’s engineering team proposed opting for metal 3D printing, which initially sparked some doubts within the Tuleap team. Frank expressed, “We had not such a good experience with this in the past due to varying tolerances, but this time it worked out very well with HLH.” SLM printing the stem and handlebars in one single structure and eliminating the need for assembly not only saved over a week worth of time but also proved to be a more cost-effective solution.
Although it was a small part, the team also had challenges developing their tail light piece. “We found specific companies specialised in light development, but the quotes were really high,” said Frank. They decided to bring this up in their meeting with HLH and were able to find a good cost-effective solution with SLA 3D printing clear ABS-like resin, painted to red.
SLA stands out as one of the fastest and cheapest way to make custom clear parts, especially lower quantities. Although there are great restraints to the degree of clarity that can be achieved when compared to vacuum casting or injection moulding PMMA, and though there is a tendency for parts to become brittle over time and subject to yellowing, for a serial production representative, SLA did the job.
Their tail was quite a big and complex part that required a smooth and high-quality finish. “We initially thought realizing it would require some type of tooling,” Frank recalled. Given that Tuleap only required quantities of two tail parts, HLH’s engineering team raised selective laser sintering (SLS) as a possible option. After consulting with HLH, the Tuleap team was able to create this part within three days and at a cost well within budget. “Very professional consultation regarding the selection of the different manufacturing technologies,” Tassilo remarked.
Apart from 3D printing, Tuleap had also source many other components from HLH for this project, including CNC aluminium and sheet metal prototypes – “great quality of all delivered scopes,” noted Tassilo. Thomas Neuheiser, responsible for part development and assembly at Tuleap, further added “you can feel it when you mount the parts on—every part has perfect tolerances.”
Despite specializing in such a versatile range of manufacturing services, HLH Rapid was still able to deliver parts to a high and consistent quality. This is owed to the fact that everything is manufactured under one roof, as it becomes easier to maintain consistent quality standards and implement rigorous quality control measures. With HLH, the Tuleap team was able to smoothly and rapidly transition towards serial production of the first bio-electric scooter, and are on schedule to launch the scooter to market.
Find out how other companies are using HLH Rapid to speed up innovation. Looking to get your prototypes or low-volume production parts made with HLH? Get in touch with our team today through our submission form or at info@hlhrapid.com.
