Say Goodbye to RangeAnxiety
Our Solution
The Result
The Story
ElectricPe is one of India’s fastest-growing EV charging platforms, founded by former Ola executives to make charging accessible and seamless. Oakter, an emerging ODM credited with shipping millions of Paytm POS devices, partnered with us to create a wall-mounted slow charger that could be manufactured at scale, deployed across India, and withstand the country’s demanding conditions.
Our role was to own the mechanical engineering and documentation up to manufacturing. A defining achievement was the single captive fastener wall-mounting system, enabling rapid installation and scalable rollout.
THE CHALLENGE
A Massive EV Base, Not Enough Charging
India has over 1.7 million electric two-wheelers, but just 12,156 charging stations. Limited fast-charging points cause long waits, downtime, and loss of income for gig workers who depend on EVs.
ElectricPe saw slow charging as the breakthrough: allowing EVs to charge overnight from a 15A socket, multiplying charging availability at minimal cost. But to realize this vision, the device had to be:
- Mass manufacturable for citywide deployments
- Outdoor safe and IP65 compliant for Indian weather extremes
- Affordable to enable adoption by small businesses
- Quick to install and easy to service
THE PROCESS
Design Progression
We partnered with Oakter as an extension of their in-house team. Our engineering approach balanced ruggedness, manufacturability, and cost control:
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- Concept to Engineering – Translating industrial design intent into a build-ready enclosure.
- Value Engineering – Reducing parts and fasteners while keeping IP65 intact.
- Material & Seal Selection – UV-stable plastics and gasket geometries sized for real-world torque scatter.
- Tolerance Analysis & Assembly Planning – Ensuring reliable sealing and fit in production and field installs.
- Documentation – Full 2D drawings, BOM, torque specs, QC checkpoints, and assembly guides for manufacturing.
THE SOLUTION
An Outdoor Charger Designed for Scale
Withstand the Sun
Units are often mounted outside mom-and-pop shops or residential walls where they are exposed to direct sunlight for hours each day. To ensure durability, we specified UV-resistant plastics that retain strength and color stability even after prolonged exposure. This reduced the risk of brittleness or yellowing, extending the product’s usable life and protecting ElectricPe’s investment.
Weatherproof It
Charging in India means dealing with dust, heavy rain, and unpredictable temperature swings. The enclosure was designed to be IP65 compliant, with robust gaskets, water-shedding edges, and carefully designed drainage paths. This not only safeguarded users from electrical hazards but also cut down on service calls by preventing moisture ingress.
Make it Affordable
For the economics of slow charging to work, the hardware had to be both reliable and cost-effective. We applied value engineering at every stage: a sandwich construction kept electrical components safely between plastic shells, while simplifying the mold tool layout. By minimizing part count and ensuring straightforward assembly, the design balanced cost savings with robust performance.
No-Fuss Mounting
A highlight of the design was the guide-rail backplate paired with a single captive fastener. Installers could slide the unit into place, secure it with one fastener, and immediately achieve a sealed fit. This reduced installation time dramatically, limited the need for training, and gave ElectricPe confidence that every deployment would be consistent. The captive design also eliminated the risk of lost hardware and added a tamper-evident feature that reassured shop owners and property managers.
THE RESULT
A Charger Ready for India’s Streets
- Rapid progression from concept to DVT and PVT readiness.
- Oakter could begin supply on aggressive timelines.
- The charger is now available via ElectricPe’s online shop, powering the expansion of India’s slow-charging ecosystem.
- Installations are quicker, safer, and more consistent thanks to the single-fastener mount.
Key Learnings
- Design for the installer: The rail plus captive fastener system cut install time and training overhead.
- Seal for the real world: Compression ribs and gasket lands accounted for torque variation across technicians.
- Affordability through simplification: Reducing steps safely created bigger savings than trimming part costs.
Buy the ElectricPe charge extension
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At Bang Design, we engineer products that balance real-world toughness, manufacturability, and speed to market. If you’re building the next EV solution or outdoor electronic device, let’s talk. We’ll help you move from concept to manufacturing-ready faster with designs that survive the field and scale with your business.