VIIALA founder expresses concerns about e-bike production misconceptions
Comments Off on VIIALA founder expresses concerns about e-bike production misconceptionsSource: Nieuwsfiets
According to Tomi Viiala, leader of the LEVA-EU member, misunderstandings about the true cost of manufacturing electric bicycles continue to persist, even among industry experts. A common assumption is that an e-bike “costs almost nothing to make”, but Viiala argues that this belief is fundamentally incorrect given the technical complexity of modern e-bikes.
Although e-bikes retain the outward appearance of traditional bicycles, Viiala explains that this familiar design masks an advanced and highly integrated technological system. “Two wheels, a frame, and handlebars give the impression of simplicity. But beneath that familiar form lies extremely compact and integrated technology,” Viiala stated in a recent LinkedIn post. He emphasised that while electric cars and motorcycles benefit from large housings for batteries, electronics, and cooling systems, bicycles offer no such space. All components must be incorporated into a lightweight frame without compromising handling, stability, or aesthetics. “Every millimeter and every gram counts,” he said.
According to Viiala, a high-quality e-bike consists of hundreds of components distributed across multiple systems. These include power electronics, battery cells with thermal management, sensors, software, wiring, displays, and mechanical parts that must function seamlessly with electronic systems. In addition to performance requirements, these elements must remain quiet, safe, reliable, easy to maintain, and ideally invisible to the rider.
Viiala stresses that the final cost of an e-bike is determined less by individual components and more by how effectively they are integrated. Factors such as thermal management directly affect battery lifespan, cable routing influences frame properties, and software defines the overall riding experience. Achieving this level of integration requires multidisciplinary teams, long development cycles, extensive testing, and close collaboration with suppliers.
The persistence of incorrect assumptions about e-bike pricing, Viiala warns, can have negative consequences for the industry. The perception that e-bikes are overpriced may pressure manufacturers to reduce investment in research and development, tooling, safety certifications, and software. “This ultimately leads to products that fall short in terms of reliability and durability,” Viiala cautioned.
He also noted that the greatest challenge in e-bike development is not simply adding advanced technology, but doing so without compromising the essence of cycling. An e-bike should feel light, intuitive, and visually refined. “The trick is to add technology without losing the bike’s character. It’s precisely this balance between performance, integration, and experience that makes e-bike development one of the most demanding product challenges in modern mobility.”
Viiala is currently collaborating with François-Henri Bennahmias on the development of a high-end e-bike featuring radically new technology, high performance, and a projected price of up to €25,000.
