ZERO SR-X Concept

ZERO Motorcycles partnered with HUGE-Design to envision a near-future electric motorcycle based on their SR-S Production bike.

Project Role: Concept Refinement / Prototype Development

Concept Development

Bill Webb, co-founder of HUGE-Design and HUGE Moto, designed the ZERO SR-X Concept Motorcycle as a passion project through rough paper-mockups, sketching and Alias 3D modelling,

Working with ZERO, Bill co-developed the initial surfacing and direction for the SR-S.

Prototype Development

Beginning with Bill’s Alias surfacing, CAD data from the SR-S production motorcycle and a fully functional motorcycle in the studio for reference, I had 6 weeks to develop all custom parts needed for the concept build.

Surface Refinement

At the end of the initial design phase, the overall surfacing was not ideal. Surfaces and edges became misaligned and too organic, losing the precision and performance characteristics of the design intent. Surfacing and edges were revised for all angles and highlights.

Further development was also needed to ensure proper ergonomics and clearance for mechanical functionality, especially around the steering and front wheel.

Part-breakup
& Intersections

Much fore-thought was necessary to plan appropriate part break-ups and assembly order; with attention to visible fasteners working aesthetically as well as retaining overall strength and rigidity.

To ensure ease of assembly, all interfacing surfaces were generously drafted and spaced to give enough ’wiggle-room’.

Parts production

Model Document and part files were sent over to the manufacturer.

Only a single run of parts could be produced in the time frame available. CNC’d ABS, Aluminum and Acrylic parts were constructed.

Test fit

Once all parts were in, everything was test fit in place to ensure fitment and functionality before paint.

Decals and secondary elements were also refined at his point.

Paint was selected (and re-selected) before final assembly.

Ready to ride

All panels fit extremely well and the final assembly yielded a strong and rigid build.

Only an appearance model was necessary, but through careful planning to ensure a streamlined assembly; the motorcycle was able to be ridden for filming and exhibit purposes.