FEATURE
The problem with this method is that you can’t be certain of the contact, and, as a result, if it will work as you put it together: You’ve got no determinant of the fact that you’ve actually welded through onto the tab - because if there are any obstructions, anything like that, there’s nothing that gives you an indication the weld is sufficient. For comparison, with our automated welding processes, as it places a piece of wire aluminium - and the wire is half a millimetre thick - onto the terminal … it does a little tug. This is, in effect, non-destructive testing. It also measures the individual deformation of each of the two wires that go onto each cell. Then the machine bonds onto the PC board with the same process, in so far as it measures the deformation of the wire. The consistency of the deformation is an indication that you’ve got the quality you want.
And this is why Synch came to your door and decided to work with Danecca Danson Joseph: You’d have to ask Chris and Matt that, but, without speaking for them, I’d say, in short, ‘Yes’. Our approach is ‘How do we use the best available components, but then add to it in a way that is unique to the UK?’ You’ll hear Chris call this “shared value of local production.”
And that’s where we’ve got our own PCB in the Synch
battery. Now this is combined with the LG M50 cells that we put in, and our means of wire-bonding onto the PCB, and then a very simple connection onto the BMS - which is also the same unit the Synch previously used: A quality item. No change needed. So, this new Danecca battery has exactly the same
interface as with previous, pre-Danecca version. Chris mentioned earlier, that this is critical to ensuring existing customers are benefiting from progress and being supported in long-term ownership.
How does this impact the person buying and using the bike?
Danson Joseph: For end users, what we’re saying is that because of the slightly different architecture and the choice of appropriate cells, we achieve a higher range. Chris Mooney: We’ve got effectively what is the same amp hour battery as we previously had but the range is, on average, somewhere between 10% to 15% more.
So the battery is less lossy, in effect? Chris Mooney: Correct. Yeah, absolutely.
Having talked about both Synch and Danecca, and heard about the battery development, how do see the next 12 to 24 months going? Matt French: We’re keen to expand our dealer network,
48 | March 2025
adding to a committed bunch who already have our bikes in their stores, giving Synch bikes floor space. Just as we’ve worked with Danecca to manufacture British-made e-bike batteries, we’ve also found a UK manufacturing partner for our Cargo bike frame. We’re in Poole. They’re a boat builder, just around the corner from us. Lots of high-end design and manufacturing experience. We’re the first business they’ve made a bike frame for. Our powder coating’s done 200 yards from where we are now. We’re lucky to be on quite a big industrial estate. So, we’ve got most of what we need not much more than a stone’s throw from our front door. One area where international supply is, currently,
unavoidable: E-bike motors. We’ve specced Bafang because of the product, the support, and the growing name recognition - you’ll have seen the EMBN factory visit content on YouTube. They’re a business that develops and manufactures product, gets brand, and understands service. We’ve always done as much as we can in-house, and when not possible we turn to recognised experts. If you’re a UK retailer, or UK bike shop, looking for a mobility-focused e-bike brand with character, and like the ethos and expertise behind Synch, we’d love to open a conversation.
Retailers keen to explore this conversation in more detail can contact Chris Mooney
chris@synchgo.com or Matt French
matt@synchgo.com Or call the Synch head office on 01202 133 433
www.synchgo.com
www.danecca.com
www.bikebiz.com
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