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If you’ve been hanging around in the world of electric bikes for any decent amount of time, you’ve probably come across Bafang. They don’t make electric bikes, but they’ve long made many of the components used by them. I visited the factory back in 2019, and recently returned for a second visit to see what had changed. Boy, was I unprepared for what awaited me…

When I say that Bafang makes many of the components found in the e-bike you probably have at home, that now seems like an understatement. With all of the new tech and developments the company has made, they now produce just about every part used in electric bike drive systems.

And not only that, but their production processes have changed significantly over the last few years.

To see behind the scenes yourself, check out my video from the visit below.

Even from the first moment I walked through the gates, the updates were apparent. Since my last visit, Bafang has moved into a massive new complex, which is important since some of their new production now includes the addition of full e-bike battery design and manufacturing. That obviously requires significantly more of a footprint than just a motor and drive system maker.

But before I get to the new battery work, let’s start at the beginning. I began my visit in the R&D department, where a dedicated team of engineers and designers work together on drawing up the next generation of e-bike components. When I visited in 2019, there were hints in the air that Bafang was working on a solution to the common issue of e-bike motors having an unfortunate tendency to wreak havoc on traditional bicycle transmissions. There’s just a limited amount of power that most bicycle shifters and derailleurs are designed for, and that amount usually falls above leg power but below motor power.

Now I was pleased to see that Bafang has several options for their own in-house developed transmissions built around internally geared hubs (IGHs). IGHs are prized in the bicycle world for their clean, low-maintenance design that completely replaces a hanging derailleur. However, the use of an internally geared hub generally means you can’t use a hub motor (or have to put it in the front wheel, which is less desirable). But not only has Bafang developed their own IGHs, but they’ve even incorporated hub motors into the design, creating multi-speed transmissions that share the same wheel hub as an electric motor. That innovation, known as the Bafang GVT line (Gear Variable Transmission), opens a whole new world of e-bike possibilities by putting an internally geared hub and a hub motor in the same product. And on top of that, the shifting occurs entirely automatically and without external cables or wires. Clever use of mechanical components keeps the entire thing sealed and without additional external components that can wear out or fail.

I was able to check out a few of these designs in Bafang’s showroom, and even tested them out later in the day on a few different e-bikes sporting Bafang’s components. But alas, I’m getting ahead of myself.

Bafang GVT-2S, an all-in-one two-speed automatic transmission and hub motor

A big part of R&D goes beyond just imagining new components. Bafang has to rigorously test their designs to ensure they can handle the harsh world in which e-bikes live. From pressure tanks of water that expose any air gaps in motors to brutal drop tests and shaker tables, the company’s engineers absolutely torture these poor devices while looking for how and where they can fail.

That testing not only leads to design improvements, but sometimes even to the development of new materials. Bafang uses their own proprietary material for the gears used in their motors, offering more strength and ruggedness than typical nylon gears, but less noise than steel gears.

There are soundproof rooms for making the most minute measurements of the sounds produced by various components, and even an EMC (electromagnetic compatibility) chamber for electrical safety testing and compliance certification, where e-bikes and components can be tested to ensure that all of the various pieces are working together properly without creating any unnecessary or potentially problematic electromagnetic radiation. This is also critical to ensuring compatability of various electrical components so that they don’t interfere with one another.

With a better understanding of the process that goes into R&D, I moved on to the factory where production occurs. Here it all begins in with quality inspections that ensure that the components that go into Bafang’s products are within manufacturing tolerances. Components like motor shells and bearings are critical to the performance of an e-bike’s drive system, and so components are scrutinized in fine detail with micron-level measurements before they make it to the factory floor where they will be incorporated into assemblies.

After passing their checks, components head into a largely automated process. For example, the motor shells are handled by robots that move them through several stages on an assembly line, adding gears, spreading grease, and receiving their motor cores.

Those motor cores pass through their own robotic lines, with the copper wire spun by precision machines. This type of work was often done by hand years ago, but has now been supplanted by automated machines that are faster and more accurate.

At this point, the sub-assemblies move to a final assembly line, one of the few places you still see a large number of human workers. Here, mid-drive motors receive their final assembly by hand. There are still several differences I noticed though, such as the lack of laser-engraved serial numbers, which have now been replaced by special stickers that retain the motor shell’s corrosion-resistant finish instead of engraving it away. The single sticker also replaces the several stickers of various sizes and shapes that use to offer a hodgepodge of information, and have now been streamlined into a single unobstrusive marker that also leaves the protective coating of the motor’s shell unaffected.

Motors are tested one final time on a bench apparatus, ensuring they meet all the correct specifications, before reaching their final stop on the conveyor belt: packaging.

Nearby, another machine sorts small parts such as nuts and washers that are included with products like hub motors, automatically bagging them to be included in the motor boxes.

It’s a similar story for several other components I saw, from handlebar displays to wiring harnesses. Much of the process has now been automated with special machines that automatically strip wires, mount connectors, glue display covers, and other steps that are highly manual and repetitive. Not everything has been replaced by robots, and you certainly still see many line workers, but a significant number of the tasks have been automated, and that seems like a trend that will continue.

One other intersting update I saw was a change to the way the soldering stations are set up. Previously, fumehoods were mounted above soldering stations that would suck out the fumes from the soldering operations.

That helps prevent those fumes from building up in the room, but the individual workers at each booth aren’t as protected since the fumes still pass by their faces.

The new setup has vacuum holes in the actual workstation surface that suck the fumes down and out through the table, preventing even the initial worker from being exposed to soldering fumes.

It’s a nicer setup that protects everyone, and I was glad to see the upgrades.

Bafang Battery Factory

The next part of the tour took me into the battery factory, which was like entering a brave new world for an e-bike parts supplier. Generally, battery factories are standalone operations run purely by battery makers. But Bafang has grown so large that at this point, it makes sense for them to invest in building their own high quality battery packs. It’s something they’ve been studying for nearly a decade, mostly staying in the R&D phase. But in the last few years, they’ve brought those designs to life and entered full battery production.

Again though, I’m getting ahead of myself. Becuase it’s that design stage that is critical to the quality and safety of batteries. Similarly to the e-bike drive system side of things, the battery factory has its own R&D section that scrutinizes different cells and batteries while preparing and testing new designs to ensure they can meet the proper safety and performance requirements set by Bafang. Assuming they do, they may end up slated for production and become one of the company’s new battery pack offerings.

Production on the factory floor starts with the individual battery cells that will eventually make up the larger battery packs. They are tested to ensure they pass quality checks before being automatically sorted by robots into the most appropriate combinations of cells based on similar internal resistances.

Computer-controlled ultrasonic welding machines then combine those battery cells into larger packs, which are encased in various enclosures depending on the specific model of battery. Before the battery cases are even sealed, each battery is put through a series of bench tests to ensure it meets the proper parameters. After the batteries pass those checks, they get sealed and sent to perform a complete testing cycle, where rows of shelves house hundreds – maybe thousands – of actively charging and discharging battery packs. After getting the green light following a successful charge and discharge cycle test, the battery is finally packaged and prepared to be sent on its way to an e-bike factory.

The scale of Bafang’s operations is nothing short of impressive. I’ve visited dozens of Chinese factories at this point but I’ve never seen such an all-encompassing operation from an e-bike component maker. With the addition of battery packs, not to mention all the other drivetrain components made by Bafang, the company truly is a one-stop shop now for e-bike OEMs.

It has been an incredible experience to see not just the components and designs, but the way that production has fundamentally changed inside of Bafang’s walls over the last several years. And at this rate, I’m fascinated to see what new innovations the next few years may bring.

Don’t forget to check out the video of this behind-the-scenes tour, below!

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Trump admin halts $5 billion NY offshore wind project mid-build

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April 17, 2025

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Trump admin halts billion NY offshore wind project mid-build

Equinor Empire Wind
Photo: Equinor

In its most aggressive attack against offshore wind yet, the Trump administration halted the $5 billion Empire Wind 1, already under construction off New York’s coast.

Norwegian developer Equinor announced yesterday that it received notice from the Bureau of Ocean Energy Management (BOEM) ordering Empire Wind 1 to halt all activities on the outer continental shelf until BOEM has completed its review. Interior Secretary Doug Burgum posted this tweet yesterday:

Burgum gave no indication of what insufficiencies there were in the approval process for the fully permitted offshore wind project, despite Trump’s recent declaration of a national energy emergency that speeds up permitting processes.

The commercial lease for the 810-megawatt (MW) Empire Wind 1’s federal offshore wind area was signed in March 2017 during the first Trump administration. It was approved by the Biden administration in November 2023 and began construction in 2024.

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The project is being developed under contract with the New York State Energy Research and Development Authority (NYSERDA). Empire Wind 1, which was due to come online in 2027, has the potential to power 500,000 New York homes.

“Halting construction of fully permitted energy projects is the literal opposite of an energy abundance agenda,” said American Clean Power Association CEO Jason Grumet in a statement. “We encourage the administration to quickly address perceived inadequacies in the prior permit approvals so that this project can complete construction and bring much-needed power to the grid.”

As Electrek reported, Equinor secured $3 billion to finance Empire Wind 1 in January. The total amount drawn under the project finance term loan facility as of March 31 was around $1.5 billion. 

As of March 31, Empire Wind has a gross book value of around $2.5 billion, including South Brooklyn Marine Terminal (pictured above), which was expected to become the US’s largest dedicated port facility for offshore wind.

In response to BOEM’s stop work order, New York Governor Kathy Hochul issued the following statement:

Every single day, I’m working to make energy more affordable, reliable and abundant in New York and the federal government should be supporting those efforts rather than undermining them. Empire Wind 1 is already employing hundreds of New Yorkers, including 1,000 good-paying union jobs as part of a growing sector that has already spurred significant economic development and private investment throughout the state and beyond.

As Governor, I will not allow this federal overreach to stand. I will fight this every step of the way to protect union jobs, affordable energy and New York’s economic future.

Equinor says it’s considering appealing BOEM’s order.

To limit power outages and make your home more resilient, consider going solar with a battery storage system. In order to find a trusted, reliable solar installer near you that offers competitive pricing, check out EnergySage, a free service that makes it easy for you to go solar. They have hundreds of pre-vetted solar installers competing for your business, ensuring you get high-quality solutions and save 20-30% compared to going it alone. Plus, it’s free to use and you won’t get sales calls until you select an installer and you share your phone number with them.

Your personalized solar quotes are easy to compare online and you’ll get access to unbiased Energy Advisers to help you every step of the way. Get started here. –trusted affiliate link*

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Jackery Earth Day Sale takes up to 50% off units with bonus savings, G-Force moto-style ZM e-bike at $800 off, Greenworks, more

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April 17, 2025

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Jackery Earth Day Sale takes up to 50% off units with bonus savings, G-Force moto-style ZM e-bike at 0 off, Greenworks, more

Leading today’s Green Deals is Jackery’s Earth Day Sale that is taking up to 50% off power stations, with many of them being marked down from the brand’s short-term Easter savings, complete with bonus savings. Among the lineup, we spotted the expandable Explorer 2000 Plus Portable Power Station bundled with a 500W solar panel at its $1,614 low. Coming up right behind it is G-Force Bikes’ Spring Sale with up to $800 in e-bike savings, the largest of which is on the moto-styled ZM All-Terrain Fat Tire e-bike that starts at $1,199 for an 80-mile trekking single-battery setup, with a double battery option not much higher. Lastly, we have a one-day-only new low price on the Greenworks 1,900 PSI Steel-Framed Electric Pressure Washer at $118, as well as a bonus cleaner attachment deal. Plus, all the other hangover Green Deals are in the links at the bottom of the page, like yesterday’s Earth Day savings on both Bluetti power stations and Lectric’s e-bike bundles, and more.

Head below for other New Green Deals we’ve found today and, of course, Electrek’s best EV buying and leasing deals. Also, check out the new Electrek Tesla Shop for the best deals on Tesla accessories.

Invest in sustainable power for on-the-go and home backup at up to 50% off with Jackery’s Earth Day Sale from $90

Jackery has officially launched its Earth Day Sale through April 25 which is lowering many of its previous Easter offers with up to 50% off a collection of power stations, solar generators, and some accessories – and we’re also seeing on-page promo codes for extra savings. One such bundle gives you the brand’s Explorer 2000 Plus Portable Power Station with a 500W solar panel for $1,614.05 shipped, after using the promo code EXTRA5 at checkout for an additional 5% off. It’s already coming down from its usual $2,949 price tag, with the bonus savings dipping that price further, back to the best we’ve seen from some of this year’s previous events. You’re looking at a combined 45% markdown here, putting $1,335 back in your pocket and equipping you with an expandable means for on-the-go and at-home backup power at the lowest price we have tracked. Like most of the deals in this sale, you’ll find this package beating out its Amazon pricing too, where it’s currently sitting $307 higher.

Grabbing this Jackery Explorer 2000 Plus bundle starts you off with a 2,042Wh LiFePO4 capacity that can support up to five extra batteries that increase things to 12,000Wh – plus, there’s the option to continue expansion with two of these setups being linked together to reach 24,000Wh. Power output here provides a steady 3,000W through the 10 ports, surging to 6,000W for larger needs, which becomes its regular output levels within expanded setups. It also has a 1,200W maximum solar input, which recharges the battery to full in two hours with six 200W panels (so around 5+ hours with the bundle here). You can also have the battery recharged via a wall outlet in two hours as well, though this doesn’t account for expandable setups.

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***Note: The extra 5% off discount has not been factored into the prices below – be sure to use the code EXTRA5 at checkout for the maximum savings!

Jackery Earth Day flash offers (through April 18):

Jackery’s Earth Day Sale home backup deals:

Jackery’s Earth Day Sale appliance backup deals:

Jackery’s Earth Day Sale outdoor backup deals:

Jackery’s accessory deals:

You can shop through Jackery’s entire Earth Day Sale on the landing page here.

G-Force ZM All-Terrain e-bike

G-Force Spring Sale drops moto-styled ZM all-terrain e-bike with 80-mile range to $1,199

G-Force Bikes is having a Spring Sale running through the rest of the month that is also being billed as a “last-chance sale” before prices increase due to tariffs, with the brand providing a countdown clock on its site. Among the up to $800 we’re seeing across the brand’s lineup of e-bikes, we spotted the ZM All-Terrain Fat Tire e-bike down at $1,199 shipped. Normally fetching $1,999 direct from the brand, with third-party sites pricing it as high as $2,499, the discounts we have tracked over the last year have mainly been seen dropping costs between $1,299 and $1,499. It’s getting the maximum savings during this sale at $800 off, dropping it to the lowest price we can find while also giving you a pair of HD wide-angle rearview mirrors free of charge, valued at $49.

The G-Force ZM e-bike borrows heavily from motorcycle styling while still retaining a street-legal class 3 status, equipped with a 750W brushless gear hub motor that can peak as high as 1,300W to deliver up to 86Nm of torque power, topping out at 28 MPH speeds. What’s more, for such an affordable price, it also provides some extensive traveling range, with the standard 20Ah single-battery option carrying you 60 to 80 miles with its five PAS levels or you can double that to 120 to 160 for just $200 more with the 40Ah dual-battery setup.

For such a low price, there’s a nice array of quality features that it brings along, like the full suspension, with an adjustable front fork and rear system for smoother riding, along with hydraulic disc brakes for guaranteed stopping power, and 20-inch puncture-resistant tires with fenders over each for those off-road ventures. That’s not all, as you’ll also find it has a 400-pound payload, a 48V LED headlight, an integrated rear light with braking functionality, a 7-speed Shimano derailleur, a wear-resistant padded bench seat with room for a passenger, a half-twist throttle for electric cruising, and a large color LCD with a USB port for charging up devices as you ride, particularly nice if you use your phone as a GPS.

G-Force’s other Spring Sale e-bike deals:

Greenworks 1,900 PSI electric pressure washer

Get rid of muck with this steel-framed Greenworks 1,900 PSI electric pressure washer at new $118 low (Today only)

As part of its Deals of the Day, Best Buy is offering the best rate yet on the Greenworks 1,900 PSI Steel-Framed Cold Water Electric Pressure Washer for $117.99 shipped. This model usually goes for $200 in full, with the discounts we’ve seen taking things as low as $120 over the past year. That rate is getting beaten out here by $2 for the rest of the day only, providing you a total of $82 in savings and marking a new all-time low. You won’t find this model currently available at Amazon, nor is it getting any discounts direct from Greenworks either. Below, you’ll also find a secondary one-day-only deal on a cleaning attachment that amplifies its capabilities.

Sporting a durable open steel frame design, the 13A motor on this Greenworks pressure washer provides you with up to 1,900 PSI at a 1.2 GPM flow rate to tackle the muck and grime along driveways, walkways, and the like. You won’t need to wrestle with pull strings, as it starts up with the press of a button, not to mention its electrical functionality, getting rid of the fumes and costs from gas – plus, it even has a waterproof plug at the end of its 35-foot power cord to ensure extra protection. You’ll have on-board storage for the included nozzles, the hose, and the metal spray gun, as well as an integrated soap tank for detergent when you need some extra cleaning power.

A secondary deal lasting the rest of the day that compliments the above or any of the brand’s pressure washers, is the 12-inch Surface Cleaner Attachment for $20.99 shipped, down from $40. It has a quick-connect feature for a faster and more effortless setup, with dual cleaning nozzles on its underside to level up the pressure washer’s cleaning power and coverage area.

Best Spring EV deals!

Best new Green Deals landing this week

The savings this week are also continuing to a collection of other markdowns. To the same tune as the offers above, these all help you take a more energy-conscious approach to your routine. Winter means you can lock in even better off-season price cuts on electric tools for the lawn while saving on EVs and tons of other gear.

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China cracks down on automated driving features after Tesla’s FSD launch

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5 hours ago

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April 17, 2025

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China cracks down on automated driving features after Tesla's FSD launch

Tesla FSD v12.5

Just after Tesla launched its ‘Full Self-Driving’ package, in China, the country announced that it cracking down on automated driving features with new limitations.

In February, Tesla launched a first version of its “Full Self-Driving” FSD package in China for owners with the latest “Hardware 4.0”, or “HW4”, vehicles.

Most of the features under Tesla’s FSD package have been limited to North America due to Tesla training its system for this market first and due to regulatory limitations in other markets.

Shortly after Tesla launched FSD in China, the American automaker had to pause its rollout due to updated requirements from China’s Ministry of Industry and Information Technology (MIIT).

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Now, MIIT has confirmed that it held a meeting with automotive industry stakeholders yesterday, and it has further clarified the rollout of advanced driver assistance (ADAS) features.

CNEV reported on the meeting:

Car companies were asked to refrain from using words like “self-driving,” “autonomous driving,” “smart driving,” “advanced smart driving,” and instead use the term “combined assisted driving” to avoid misleading consumers, according to the minutes of the meeting.

Tesla had already changed the name from ‘Full Self-Driving’ to “Intelligent Assisted Driving” following the launch in China.

Based on a statement from MIIT, the meeting focused on enforcing the previously announced updated requirements that launched right after Tesla introduced FSD in China (translated from Chinese):

The meeting emphasized that automobile manufacturers must deeply understand the requirements of the “Notice”, fully carry out combined driving assistance testing and verification, clarify the system functional boundaries and safety response measures, and must not make exaggerations or false propaganda. They must strictly fulfill their obligation to inform, and truly assume the main responsibility for production consistency and quality safety, and truly improve the safety level of intelligent connected vehicle products.

Regulators want automakers to reduce the frequency of new software updates and instead focus on extended testing before releasing new updates.

The last few months have been quite chaotic for ADAS systems in China. Along with Tesla’s FSD release, several Chinese companies released their systems, including BYD, Xiaomi, and Huawei.

Xiaomi reported a fatal accident in which its ADAS system was active just seconds before the crash, and Tesla owners using FSD racked up thousands of dollars in fines due to FSD making mistakes.

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