I visited Ride1Up’s e-bike factory to find the secret behind good quality, low-cost e-bikes
I’ve been riding Ride1Up e-bikes since just about their first model. Over the many years since I first threw a leg over that bike, I’ve watched the company roll out an ever-increasing lineup of diverse e-bikes that all shared one common trend: great bang for your buck.
So when I was recently touring Asia to visit micromobility factories for a peek behind the curtain, I knew Ride1Up’s factory would be high on my list. They invited me out to join the company’s founder, Kevin Dugger, on a tour of the factory so I could see just how Ride1Up goes about ensuring they can keep the quality high and the prices low.
Like nearly every other e-bike company in the US, their bikes are produced in China. But you can get a wide range of quality across such a large country with vast manufacturing facilities. If you cheap out, you get cheap products. But if you design a production system with triple and quadruple quality-assurance inspections, you get well-made products that treat their owners right for years to come.
That’s the calculation Ride1Up made, and it’s paying dividends for the company in reducing customer issues and thus, customer complaints. And when you have as generous of a return policy as Ride1Up, you darn well better make sure people get their bikes in good shape and that those bikes last as long as riders expect them to.
My tour of Ride1Up’s factory took me straight onto the factory floor where parallel production lines were busy cranking out Ride1Up’s ultra-affordable $995 Portola folding e-bike on one side of the factory, and the company’s budget-priced $2,295 CF Racer1 carbon fiber road/gravel e-bike. And yes, when it comes to carbon fiber road and gravel e-bikes, 2 g’s is crazy low-priced.
To see a tour of the factory and learn the secrets behind making high-quality e-bikes, check out my video below. And don’t forget to keep reading below for even more detail!
Before parts get to either of those lines though, they first go through pre-check. Wheels are built up around motors and front hubs using automated lacing machines that then feed into automated checking robots to ensure they’re properly laced and tensioned.
Any wheel that doesn’t come out exactly right is shunted off to a side chute where a human inspector can evaluate it and send it back for reworking until it’s perfect.
The process combines both manual and automated tasks, drawing from the best of both types of resources.
Frames are inspected at this point too, having been sent in from another off-site welding and painting building (as Ride1Up’s factory is located in a lower-emissions area).
The frames are inspected for any paint knicks or imperfections, and any frames with issues are marked for repair before being sent off for assembly.
The rest of the frames move on to the assembly line.
Those pre-inspected frames are hoisted off to the initial assembly area by an elevated conveyor, where initial assembly will begin.
On the other side of the conveyer, a worker receives the frame and sets it up at its first station so that lights can be installed on the rear rack and internally run cables can be passed through the frame tubes.
Controllers are then installed into the frames, but only after being scanned into an intelligent management system that digitally pairs each component with the bike frame. This is used for accountability in the future. If a component is ever found to be defective, such as if a controller manufacturer reports back that a certain batch of 20 controllers has an issue, Ride1Up can instantly know which bikes may be affected and can trace that exact bike and controller to its owner, even months or years later.
For the Portola folding e-bikes, the frames are then ready to be loaded on the assembly line’s conveyor system, which slowly moves down the line to each worker’s station.
The first step is to install the pedal drivetrain, which includes the bottom bracket, chainring, cranks, and pedals. Next the folding hardware is installed, followed by the kickstand and the rear wheel with the motor. Each component is held on using specially treated hardware designed for corrosion resistance, with bolts having thread locker compound applied to ensure they don’t shake loose.
The handlebars are then mounted to the frames along with the front fork. With the handlebars mounted, the wiring, shifter cable, and brake hoses can all be routed up to the bars. Wire wraps are applied to make the wiring hardness look neat and tidy, and then a battery is installed. Just like the controller, major parts like the motor and battery are also scanned and recorded so that documentation exists for each e-bike to maintain a record of its entire parts list.
The tools used in each step are also regularly calibrated using sophisticated electronic tools, ensuring that if a bolt requires 10 Nm of torque to be applied, the torque wrench is truly outputting 10 Nm of torque.
Reaching the end of the automated conveyor system, the e-bikes are flipped onto their wheels and rolled over to a finishing station, where another worker indexes the shifter, calibrating it so that all of the gears shift crisply and without jumping.
On this day, the parallel line was assembling the carbon fiber CF Racer1 e-bike. Only the most experienced workers are put on this assembly line due to the higher tolerances of carbon fiber bike work. There also aren’t any power tools used on this line; all of the assembly steps are performed using precision hand tools to avoid applying too much stress to the carbon fiber frame.
The general steps are similar to those seen on the first assembly line, but performed with an even higher level of sophistication. Frames are first visually inspected to weed out any imperfections before being hoisted along a hanging conveyor system to the assembly line. From there, workers install the controllers, batteries, wheels, handlebars, shifter, pedal drivetrain, and any other hardware.
After reaching the end of the assembly line, the bikes are rolled off to their own finishing area, where the brake lines are bled and the shifter is calibrated.
Once fully-assembled, both bike models are rolled off into their own corrals, where they await visual inspection. Quality testers go over the bike to inspect dozens of points and ensure they are assembled correctly.
Any issues are marked and the bikes are rolled off into a side corral for remediation. The intelligent tracking system also correlates the issue to the worker who performed that task, allowing the factory to root out systematic issues by immediately addressing any mistakes that a worker might make. Workers with few or no mistakes also get monetary bonuses to their salary, providing further incentive for the bikes to be assembled perfectly the first time.
The approved bikes are then passed onto the next stage of ride testing.
At this point, none of the e-bikes have any saddles. That’s because they’re all ride-tested to ensure all functions are working properly, and these workers use the same seats that are switched from bike to bike. The actual saddle that ships with the e-bike is added just before packaging, ensuring that when a customer eventually opens their e-bike, theirs are the first cheeks to grace that saddle.
Once the bikes pass their ride testing, they are considered complete, though they aren’t yet ready for packaging.
Before the e-bikes can be packed up, they first must go through a series of third-party inspections. These outside contracted inspectors aren’t Ride1Up’s factory employees, but actually work somewhat antagonistically with them. Their job is to redo all of the inspections and find anything that was missed in the several previous rounds of inspections.
Because they are technically not Ride1Up’s factory employees and instead come from an outside inspection agency, they approach the inspections differently and are better positioned to find any issues that could have slipped through the previous several rounds of in-house inspections.
Only once the e-bikes pass third-party inspections are they considered ready for boxing up. At that point, they head to the last conveyor belt of their journey, which sends them along a packaging routine that has been meticulously refined by Ride1Up over several years. The company has applied the experience of shipping tens of thousands of e-bikes to find ways to best protect the bikes while also minimizing the amount of plastic and foam used in the process.
As I looked through the packaging steps, I couldn’t find any foam traditionally used in bicycle packaging, and the only plastic I saw were the cable ties and a single piece of soft plastic used to protect the fork.
Interestingly, there was still one final inspection point applied even after boxing up the e-bikes. The entire box is precision weighed, which ensures it comes out to the exact right weight.
If a single component or piece of packaging was forgotten, the box would be too light and the factory would know there was an issue.
It’s just the cherry on top of an entire system full of redundant safety and quality inspections performed before, during, and after the assembly process.
I’ve seen a lot of e-bike factories in my years covering the industry, but it’s rare to see this many spot checks and quality assurances built into so many different areas of the production and assembly process.
The tour was a fascinating look behind the curtain of how Ride1Up builds its e-bikes, and helps answer the question of how they can offer so much value.
As a direct-to-consumer company, they have to offer e-bikes that work well right out of the box. These e-bikes are being shipped largely to private customers, not bike shops and professional assemblers. So they have to be ready to roll, without the need for repairs, right from day one. Anything else would result in a costly return process for Ride1Up.
Over the years, they have refined their system for building quality e-bikes that are built to last while still offering a reasonable price point for riders.
I’ve long touted the company’s quality and performance from my own testing of their various e-bike models. But that was always merely the end of the story – riding the finished product. Now, having seen the assembly and quality inspections firsthand, I can finally vouch for their professionalism from the very start of the process.
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GM may have decided to pull the plug on the forward-looking Chevy Brightdrop electric van a few months ago, but don’t let that stop you, but don’t let that fool you. Right now might be the best time ever to get your hands on one.
SKIP THE STORY: jump right to the deals (trusted affiliate link).
It’s hard to overstate how good the deals on Chevy’s Brightdrop got while GM was still trying to build up demand for its fleet-focused van, and now that the company has decided to stop production, the deals have gotten even better, with a newly announced $699 lease for 39 mo. with $2,999 down through January 2nd — and that’s before you factor in an additional $3,000 discount reserved for Costco Executive Members!
Despite that, I’ve heard more than one fleet manager express hesitation at the thought of adding a discontinued product to their fleet, even if it is a killer discount. To them, I offer the following, model-agnostic rebuttal:
Legacy brands support their products
Companies like GM aren’t going anywhere soon, and neither are the customers they’ve spent millions of dollars acquiring over the past several decades. They’ll keep building parts and offering service and maintenance on vehicles like the Brightdrop for at least a decade — not least of which because they have to!
GM sells each Brightdrop with a minimum 8 year/100,000 mile warranty on the battery and other key components, which can be extended either through GM itself or through reputable third-party companies like Xcelerate Auto for seven more.
There are precious few large fleets out there looking at 15 year, 200-plus thousand mile vehicle replacement cycles. For those that are, however, all indications so far are that the vehicle’s battery health and general performance will still be well within usable limits.
So, yes: parts longevity and manufacturer support will be there (something I’d be less confident about with a startup like Rivian or Bollinger, for example), but there’s more.
Section 179 and local incentives
The One Big, Beautiful Bill Act (OBBBA) of 2025 gutted America’s energy independence goals and ensuring its auto industry would fall even further behind the Chinese in the EV race, but the loss of Section 45W wasn’t the only change written into the IRS’ rulebook. Section 179, an immediate expense reduction that business owners can take on depreciable equipment assets, has been made significantly more powerful for 2025.
The section 179 expense deduction is limited to such items as cars, office equipment, business machinery, and computers. This speedy deduction can provide substantial tax relief for business owners who are purchasing startup equipment.
The revised Section 179 tax credit (or, more accurately, expense reduction) allows for a 100% deduction for equipment purchases has doubled to $2.5 million, with a phase-out kicking in at $4 million of capital investments that drops to zero at $6.5 million. That credit and can be applied to new and used vehicles, as well as charging infrastructure, battery energy storage systems, specialized tools, and more (as long as they’re new to you).
What’s more, with regional incentives like the up to $15,000 off a new medium-duty van available from Illinois utility ComEd, the net cost of GM’s $699 promo lease drops to ~$315/mo., and there is still state money out there, as well, depending on where you live.
All of which is to say: don’t let a little thing like GM discontinuing the Brightdrop convince you to skip it. If you do that, the bean counters that killed off the Buick Grand National, GMC Syclone, and Pontiac Fiero win.
SOURCE | IMAGES: GM Envolve.
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US Energy Information Administration (EIA) data released on November 25 and reviewed by the SUN DAY Campaign reveal that, during the first nine months of 2025 and for the past year, solar and battery storage have dominated growth among competing energy sources, while fossil fuels and nuclear power have stagnated.
Solar set new records in September
EIA’s latest “Electric Power Monthly” report (with data through September 30, 2025), once again confirms that solar is the fastest-growing source of electricity in the US.
In September alone, electrical generation by utility-scale solar (>1 megawatt (MW)) ballooned by well over 36.1% compared to September 2024, while “estimated” small-scale (e.g., rooftop) solar PV increased by 12.7%. Combined, they grew by 29.9% and provided 9.7% of US electrical output during the month, up from 7.6% a year ago.
Moreover, generation from utility-scale solar thermal and photovoltaic systems expanded by 35.8%, while that from small-scale systems rose by 11.2% during the first nine months of 2025 compared to the same period in 2024. The combination of utility-scale and small-scale solar increased by 29.0% and produced a bit over 9.0% (utility-scale: 6.85%; small-scale: 2.16%) of total US electrical generation for January-September, up from 7.2% a year earlier.
And for the third consecutive month, utility-scale solar generated more electricity than US wind farms: by 4% in July, 15% in August, and 9% in September. Including small-scale systems, solar has outproduced wind for five consecutive months and by over 40% in September.
Wind leads among renewables
Wind turbines across the US produced 9.8% of US electricity in the first nine months of 2025 – an increase of 1.3% compared to the same period a year earlier and 79% more than that produced by US hydropower plants.
During the first nine months of 2025, electrical generation from wind plus utility-scale and small-scale solar provided 18.8% of the US total, up from 17.1% during the first three quarters of 2024.
Wind and solar combined provided 15.1% more electricity than did coal during the first nine months of this year, and 9.8% more than the US’s nuclear power plants. In fact, as solar and wind expanded, nuclear-generated electricity dropped by 0.1%.
Renewables are now only second to natural gas
The mix of all renewables (wind, solar, hydropower, biomass, and geothermal) produced 8.7% more electricity in January-September than they did a year ago, providing 25.6% of total US electricity production compared to 24.2% 12 months earlier.
Renewables’ share of electrical generation is now second to only that of natural gas, which saw a 3.8% drop in electrical output during the first nine months of 2025.
Solar + storage have dominated 2025
Between October 1, 2024, and September 30, 2025, utility-scale solar capacity grew by 31,619.5 MW, while an additional 5,923.5 MW was provided by small-scale solar. EIA foresees continued strong solar growth, with an additional 35,210.9 MW of utility–scale solar capacity being added in the next 12 months.
Strong growth was also experienced by battery storage, which grew by 59.4% during the past year, adding 13,808.9 MW of new capacity. EIA also notes that planned battery capacity additions over the next year total 22,052.9 MW.
Wind also made a strong showing during the past 12 months, adding 4,843.2 MW, while planned capacity additions over the next year total 9,630.0 MW (onshore) plus 800.0 MW (offshore).
On the other hand, natural gas capacity increased by only 3,417.1 MW and nuclear power added 46.0 MW. Meanwhile, coal capacity plummeted by 3,926.1 MW and petroleum-based capacity fell by an additional 606.6 MW.
Thus, during the past year, renewable energy capacity, including battery storage, small-scale solar, hydropower, geothermal, and biomass, ballooned by 56,019.7 MW while that of all fossil fuels and nuclear power combined actually declined by 1,095.2 MW.
The EIA expects this trend to continue and accelerate over the next 12 months. Utility-scale renewables plus battery storage are projected to increase by 67,806.1 MW (a forecast for small-scale solar is not provided). Meanwhile, natural gas capacity is expected to increase by only 3,835.8 MW, while coal capacity is projected to decrease by 5,857.0 MW, and oil capacity is anticipated to decrease by 5.8 MW. EIA does not project any new growth for nuclear power in the coming year.
SUN DAY Campaign’s executive director Ken Bossong said:
The Trump Administration’s efforts to jump-start nuclear power and fossil fuels are not succeeding. Capacity additions from solar, wind, and battery storage continue to dramatically outpace those from gas, coal, and nuclear, and by growing margins.
Read more: EIA: Solar + storage dominate, fossil fuels stagnate to August 2025
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The bZ3X is off to a strong start as Toyota’s most affordable electric SUV, starting at around $15,000 in China.
The bZ3X is a $15,000 Toyota electric SUV in China
Toyota’s joint venture, GAC Toyota, launched the bZ3X in China this March, an affordable, compact electric SUV aimed at young families.
The bZ3X is Toyota’s “first 100,000 yuan-level pure electric SUV,” starting at just 109,800 yuan, or roughly $15,000.
By May, the electric SUV was the best-selling foreign-owned EV in China, beating out the Volkswagen ID.3, Nissan N7, BMW i3, and Volkswagen ID.4 CROZZ.
According to the latest update, the bZ3X remains a hot seller. GAC Toyota announced that bZ3X sales exceeded 10,000 units for two consecutive months, with 10,010 units sold in November. Cumulative deliveries have now surpassed 62,000 units.
GAC Toyota recently put the electric SUV through rigorous testing on a winter road trip across China, “showcasing its impressive capabilities as a 100,000-yuan-class pure electric vehicle.”
Measuring 4,645 mm in length, 1,885 mm in width, and 1,625 mm in height, the bZ3X is about the same size as BYD’s popular Yuan Plus (sold as the Atto 3 overseas).
Inside, the electric SUV is a major upgrade over the Toyota vehicles we’re accustomed to, with advanced ADAS features, smart storage, and large digital screens.
The bZ3X is available in seven different trims in China, two of which include a LiDAR. Upgrading to the LiDAR version costs 149,800 yuan ($20,500).
Toyota’s electric SUV is available with 50.04 kWh and 67.92 kWh battery pack options, providing a CLTC range of 430 km (267 miles) and 610 km (379 miles), respectively.
Less than two weeks ago, GAC Toyota launched pre-sales for the bZ7, a new flagship electric sedan. According to Toyota, the new flagship EV “possesses a higher level of intelligence than any of Toyota’s offerings in global markets,” as the automaker fights to regain market share in China’s fierce auto market.
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