How one Fanshawe student built a custom electric bike

Philip Beausoleil created a custom e-bike for his capstone project in the Fabrication Lab.
A Fanshawe student from the Electromechanical Engineering program has spent the fall semester building a custom e-bike.
Philip Beausoleil is a dedicated two-wheeled transportation enthusiast and an experienced electric bike mechanic. With state-of-the-art features, this bike achieves speeds of up to 100 km/h, powered by a robust 3,000-watt motor and a high-capacity battery capable of travelling from London to Waterloo.
Going beyond speed and range, Beausoleil incorporated industrial-grade hardware to allow for the future integration of advanced technologies such as blind spot detection, adaptive cruise control, lane-keep assist, and security cameras to monitor activity when parked—similar to features seen in Tesla vehicles.
In a family steeped in engineering and trades, Beausoleil found his niche in electromechanical engineering, a discipline blending design and hands-on problem solving.
“I come from a big family of makers and tradesmen doing anything from framing electrical to millwright and tool and die,” he said.
Beausoleil’s passion for research, novel design, and building drove him to invest 425 hours into his capstone project. He meticulously created digital models of all the components from concept to completion, testing their fits and clearances before progressing to a practical prototype. Much of his work occurred in Fanshawe College’s Fabrication Lab, where he utilized resources like 3D printers, soldering stations, and a laser cutter. These tools enabled him to fabricate body panels and templates for his design quickly.
Beausoleil also leveraged the college’s machine shop, employing precision tools such as the lathe and mill, welding equipment like the metal inert gas (MIG) and the tungsten inert gas (TIG) machines, as well as a plasma cutter in the welding shop. These resources were instrumental in manufacturing higher-precision components for the project.
“I was able to talk with the professors in the different shops and get a lot of guidance and facilitation before going in and machining it, welding it, working on the metal work for the body, and doing some of the sewing. Without the support of the techs, professors, and the college itself, I would not have been able to get this bike done in time.”
Beausoleil revealed that his inspiration for the e-bike stemmed from wanting a capstone project showcasing his skills in every program area. He drew inspiration from past student projects, like a pneumatic T-shirt cannon, but created something uniquely tied to his passion. He began with a detailed research phase, selecting and sourcing components globally, including some industrial-grade hardware that was difficult to find locally.
“I did a lot of mental design for about two weeks before I even touched any paper,” Beausoleil explained. Once ready, he created a comprehensive Computer-aided design (CAD) model using SolidWorks to ensure all components fit seamlessly. From there, he progressed to building and testing his prototype.
Beausoleil faced challenges, particularly with time management. He set strict deadlines, dedicating the first month entirely to design and starting assembly only in November.
“For 81 days, I went from concept to a fully built, welded, and functional bike. It was a massive accomplishment,” he said.
One of the most innovative aspects of his project is its potential for future advancements. Beausoleil envisioned integrating blind spot detection, lane-keep assist, and adaptive braking systems using radar and AI-powered optical sensors.
“These are features we see in cars, and I believe motorcycles should benefit from them too,” he noted.
Despite these ambitions, Beausoleil acknowledged the hurdles of making his e-bike street-legal. He’s exploring avenues to obtain insurance and address infrastructure challenges for electric vehicle charging.
“As a research vehicle, it’s not hardened against the elements, and I live in an apartment without charging facilities,” he added.
Looking ahead, Beausoleil is excited about a career in systems integration engineering, where he can tackle new challenges and innovate further. He’s also exploring electrification projects and industry opportunities, eager to shape the future of sustainable transportation.