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Swytch Bike: Pocket-Sized Battery, Full-Sized Problems
In 2022 Swytch launched a market-leading eBike battery the size of a power bank. Getting there meant packing 36V and 20A peak power into a pocket-sized pack with a 5mm-deep connector, then making it survive 5,000 connection cycles, drop, vibration, salt-spray and 1,000 charge cycles — at a price that would sell 100,000 units.
This is the unvarnished engineering story behind that product: six full-system prototype loops, a custom BMS that overheated in testing, EMC failures from packing too much into too little space, a mount architecture designed "user-friendly first" that had to be thrown away and rebuilt "robust first", and a DFM stage that resurrected problems the team thought were solved.
Dmitro will also share the lessons the R&D numbers taught him: why one product generation's development budget was an order of magnitude bigger than the last (and why more budget didn't mean better outcomes), when custom beats off-the-shelf, co-developing with suppliers in China versus building an on-shore R&D lab, and how a supply-chain crisis reshaped his development philosophy.
Design engineers and R&D leads will leave with a practical framework for scoping custom development, testing to failure, and shipping before perfection
This is the unvarnished engineering story behind that product: six full-system prototype loops, a custom BMS that overheated in testing, EMC failures from packing too much into too little space, a mount architecture designed "user-friendly first" that had to be thrown away and rebuilt "robust first", and a DFM stage that resurrected problems the team thought were solved.
Dmitro will also share the lessons the R&D numbers taught him: why one product generation's development budget was an order of magnitude bigger than the last (and why more budget didn't mean better outcomes), when custom beats off-the-shelf, co-developing with suppliers in China versus building an on-shore R&D lab, and how a supply-chain crisis reshaped his development philosophy.
Design engineers and R&D leads will leave with a practical framework for scoping custom development, testing to failure, and shipping before perfection
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