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For fit mountain bikers looking for a lightweight E-Bike, there’s only one real option available to you: an E-Bike equipped with the Fazua motor system. The motor can both be removed  from your bike and is completely resistance free above the 25 km/h assistance limit. Fazua, from the Bavarian slang for “Drive on!”,  has existed since 2012 and the Startup now has 60 employees. We went for a visit at Fazua’s home in Ottobrunn near Munich.

Video: Fazua factory visit

At 15-minutes, this is quite a long video, but there was just far too much to see and we wanted to show you it all. Have fun!
(the video is German, we included english captions for you)

In photos

We’ve collected the highlights of our visit below. Have fun as you explore Fazua HQ.

The new headquarters in Ottobrunn
# The new headquarters in Ottobrunn - the 60 employees of Fazua work directly next to Airbus
EADS used to do literal rocket science in the left building
# EADS used to do literal rocket science in the left building - on the right a new building that Fazua will be using soon
New employees are greeted in the stairwell
# New employees are greeted in the stairwell - Fazua is planning to hire a new employee every month until October next year!
Fazua has grown from a start-up to a mid-sized business
# Fazua has grown from a start-up to a mid-sized business - including HR, Buying, Distribution, Service... by October 2019 there will be 100 employees here
Wood and paint helped sell the idea when it was still a concept
# Wood and paint helped sell the idea when it was still a concept - this model helped gather the first round of investment in 2012
Motor, battery and control unit can be removed from the down tube
# Motor, battery and control unit can be removed from the down tube - the basic idea hasn't changed since the first "prototype"
Fazua doesn't develop frames
# Fazua doesn't develop frames - but the sleek integration into the frame means they have to work closely with manufacturers
Philipp Kalläne
# Philipp Kalläne - the co-founder leads development for Fazua
Does induction lead to inspiration
# Does induction lead to inspiration - just a little showpiece in the electronics lab
Electronics development
# Electronics development
Two laptops, two mice, smartphone, notebook, control units
# Two laptops, two mice, smartphone, notebook, control units - now that's some multi-tasking
Without suppliers it wouldn't be possible to make an E-Bike motor
# Without suppliers it wouldn't be possible to make an E-Bike motor - despite this, it's interesting how much is developed, tested and assembled here in Ottobrunn
This is where software and electronics get developed
# This is where software and electronics get developed - even if this baby motor isn't quite suited for an E-Bike
These employees are assembling the gearbox for the bottom bracket
# These employees are assembling the gearbox for the bottom bracket - The crank spindle, sensors and bevel gears all get mounted in the housing
ESD stands for Electrostatic Discharge
# ESD stands for Electrostatic Discharge - that means you're not getting in here wearing Vans
Special mounts makes assembly easier
# Special mounts makes assembly easier
The control unit gets moved from one station to the next on this rail
# The control unit gets moved from one station to the next on this rail
The heart of the system
# The heart of the system - these motors get delivered from Switzerland
Neat soldering is essential
# Neat soldering is essential
Solder, place, screw and glue
# Solder, place, screw and glue - Working in sync
QR codes and serial number allow traceability of parts
# QR codes and serial number allow traceability of parts
Mounts make assembly easier and more precise
# Mounts make assembly easier and more precise
Loctite, but from a big bottle
# Loctite, but from a big bottle - lots of motor systems go through here
A tube of bolts is essential
# A tube of bolts is essential - to be able to assemble all of these units
Karla, Production Engineer
# Karla, Production Engineer - the Ecuadorian developed the production lines
When the system is assembled, it gets tested here
# When the system is assembled, it gets tested here - if it passes the test, it gets packed up and stored ready to be sent out
The laser marking station with mount for the motor
# The laser marking station with mount for the motor - this allows the gearbox to be identified later
The laser creates a permanent 'engraving'
# The laser creates a permanent 'engraving' - that means the safety instruction will always be legible
After the laser marking, the unit gets cleaned
# After the laser marking, the unit gets cleaned - then it's all ready to go
Finished bottom bracket gear boxes
# Finished bottom bracket gear boxes - the integrated sensor measured torque and cadence
Looks pretty neat
# Looks pretty neat - and makes us ask why there are so many bikes with boring paint jobs...
E-Bike and art 1
# E-Bike and art 1
E-Bike and art 2
# E-Bike and art 2 - various artist create the art that matches the bike. Or bike to art? Who knows..
Pedaling seated or standing exerts different loads
# Pedaling seated or standing exerts different loads - this test machine can simulate a variety of scenarios
No rest for the motor
# No rest for the motor - there's just a little bit of "wind" to help keep it cool
Long-distance riders
# Long-distance riders - six bikes ride for glory, 24/7
How does the gear box and bottom bracket withstand different riding conditions?
# How does the gear box and bottom bracket withstand different riding conditions? - This test station loads the bottom bracket with the motor running at full power
Loud and bumpy
# Loud and bumpy - this bike is having a hard time on the rough-roads test. Even here nothing is allowed to fail
When Johannes Biechele, one of the founders is "On Air"
# When Johannes Biechele, one of the founders is "On Air" - do not disturb
Marketing is still a little bare
# Marketing is still a little bare - and is this a new, extra thin version of the Fazua motor for dirt bikes?
Not everything is automated at Fazua
# Not everything is automated at Fazua - sadly the fridge has to be restocked by hand

Interested in more? You can find our other factory visits and looks behind the scenes of various parts of the bike industry here.

This post is also available in: deDeutsch

  1. benutzerbild

    rik

    Registered since 12/2015

    For fit mountain bikers looking for a lightweight E-Bike, there’s only one real option available to you: an E-Bike equipped with the Fazua motor system. The motor can both be removed  from your bike and is completely resistance free above the 25 km/h assistance limit. Fazua, from the Bavarian slang for “Drive on!”,  has existed since 2012 and the Startup now has 60 employees. We went for a visit at Fazua’s home in Ottobrunn near Munich.


    → Read the full article “[url=https://www.emtb-news.de/news/en/fazua-e-bike-motors-factory-visit/]Factory visit: Fazua E-Bike motors[/url]”


    [url=https://www.emtb-news.de/news/en/fazua-e-bike-motors-factory-visit/][img]https://fthumb0.mtb-news.de/cache/750_auto_1_1_0/12/aHR0cHM6Ly93d3cuZW10Yi1uZXdzLmRlL25ld3Mvd3AtY29udGVudC91cGxvYWRzLzIwMTgvMTIvRmF6dWEtMzctMS5qcGc.jpg[/img][/url]
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