Electric Skateboard
THE CHALLENGE
We’re living in the era of rideable technology and micro-mobility, where electric devices help us move faster and more efficiently. A startup approached our team to take on the challenge — asking us to develop the electrical system, mechanical components, and firmware for a next-generation electric skateboard designed to redefine the riding experience.
The Opportunity
AJProTech has partnered with a crowdfunded startup from Singapore to bring skateboarding into a new era of technology. Our engineers leveraged their expertise to make even a traditional skateboard smarter. We equipped each wheel with direct-drive brushless motors for greater speed, added heavy-duty swappable batteries for extended ride time, and designed a sleek BLE remote to seamlessly control speed and charging.
THE SOLUTION
We developed several skateboard versions: a standard electric skateboard with two motors and one battery, and a longboard equipped with four motors and two batteries. Unlike traditional e-skateboards that use belt-driven or in-hub motors, this board features a helical drive system for smoother riding and reduced rolling resistance. A swappable battery pack provides extended range in a lightweight design, while still allowing riders to push manually like a regular longboard. A handheld remote with a throttle wheel ensures precise control, smooth acceleration, and regenerative braking for an enhanced riding experience.
24 mph Top Speed
20 miles Extended Range
Bluetooth 5.0 Remote Controller
Swappable Battery
Longboard
2 Batteries
4 Motors
Skateboard
1 Battery
2 Motors
Mechanical design
The AJProTech team faced a unique challenge: keeping the familiar skateboard design while adding advanced mechanical features.
The Board’s deck is crafted from vertically laminated bamboo, reinforced with bi-axial fiberglass for extra durability. It measures 42 inches long and 9 inches wide, providing a sturdy yet lightweight ride.
The drivetrain features a helical gear with a 2:1 ratio, allowing the dual-motor version to reach speeds of up to 24 mph with a range of 20 miles. The carbon steel gears undergo induction treatment for extra strength, and we use high-tech grease – originally designed for large ships – to extend drivetrain life and withstand tough conditions.
Electrical engineering
To ensure smooth performance, the Board runs on two VESC controllers integrated into a single PCB, optimizing motor efficiency. Upgraded capacitors improve power management and regenerative braking, especially when the battery is fully charged. The swappable battery system adds convenience, allowing for longer, uninterrupted rides.
Performance Features:
- Custom Compact Controller: Optimized for High-Torque BLDC Servo Motor, offering reliable performance in a reduced form factor.
- All-Wheel-Drive Compatibility: Uses the same motor units, paired via BLE radio, enabling synchronized operation.
Electronics & Connectivity
- PCB Protection: Current PCBs are coated with conformal protection, safeguarding against water and dirt exposure.
- Phase Wire Connectors: Uses 3.5mm bullet connectors, soldered directly to the PCB for a secure and reliable connection.
- Encryption & Security: Secure encrypted communication between the remote and board prevents signal interception.
Remote Control & Safety Features
- Control Interface: Spring-Loaded Wheel – Equipped with a Hall sensor for precise throttle and braking adjustments.
- Safety Mechanism: Instead of a physical “deadman” switch, the remote features a sensor-based detection system.
If the rider drops or releases the remote, the board automatically applies light braking, ensuring a safer stop.
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Firmware design
For this project, we developed custom firmware that enables smooth contactless communication between the remote controller and electric skateboard. The Bluetooth Low Energy (BLE) remote with E-Ink display automatically wakes up when picked up and instantly connects to the board. A key advantage is its universal compatibility – the same remote works perfectly with both longboard and skateboard models while clearly displaying real-time riding data including speed, battery level, and connection status. This streamlined solution eliminates the need for multiple controllers while maintaining reliable performance.
Remote controller
We designed this remote from scratch, incorporating an E-Ink display, thumbwheel for precise speed and braking control, and automatic hand-detection sensors. The intuitive operation requires no buttons — simply pick up the remote and it automatically powers on and connects to your board. Rotate the wheel forward to accelerate or pull back to brake smoothly.
A key innovation is dual-motor synchronization, allowing the remote to control two longboard drives simultaneously while maintaining perfect speed alignment. Riders can customize their experience through multiple performance modes and create personalized driver profiles that adjust throttle response and braking sensitivity directly from the remote settings.
- Connectivity: Utilizes BLE 5.0 for seamless communication with the motor controller, enabling reliable command transmission.
- Display: Features an E-ink screen for real-time ride data, including speed, battery level, and key metrics.
- Charging & Battery Life: Supports USB-C charging with an extended battery life of up to one month per charge.
- Embedded Firmware: Optimized for four microcontrollers, including Texas Instruments, Atmel, and STM, ensuring high performance and advanced capabilities.
Prototyping
Our in-house engineering lab accelerates hardware development with rapid prototyping and comprehensive testing capabilities. We maintain a network of specialized manufacturing partners to quickly produce functional prototypes, including custom PCB assemblies, precision-machined enclosures, and tailored electromagnetic components.
Assembly
The electric skateboard features tool-free modular assembly and a 30-second hot-swap battery system. Universal components with click-and-ride connections enable complete setup in under 5 minutes, while the battery packs deliver 20+ miles per charge. The rugged modular design maintains full performance across different conditions while enabling easy upgrades and field repairs.
Impact
We designed and developed the complete product solution, including mechanical systems, electronics, and firmware, through multiple prototype iterations. Throughout the process, the client actively participated in hands-on assembly and real-world testing, providing critical feedback that informed final design refinements.
Our team delivered a complete production-ready package consisting of optimized CAD files, validated firmware, and comprehensive testing procedures. These deliverables enabled the client to successfully transition the product into mass production at their selected manufacturing facilities, with our technical team available to provide consultative support during the production ramp-up phase.
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