Joel Wengström from Sweden recently completed his diploma in Industrial Design at the Konstfack University of Arts, Crafts, and Design. His project, the “Polestar Exö,” is a motorcycle design featuring a Bio-Composite Exoskeleton inspired by scorpions. This innovation draws from the natural world, particularly the exoskeleton of scorpions, to introduce a novel manufacturing method using bio-composite materials.
Polestar
Joel selected Polestar due to his admiration for their design and his desire to work with a Swedish company. His goal was to enhance his skills in analyzing form and grow in the field of design. Joel reached out to Polestar and arranged a meeting with Juan Pablo Bernal, the Design Director, and Jonas Göthlin, a Technical Expert. They suggested it would be intriguing for him to explore ways to minimize material usage and utilize Bcomp, a flax-based bio-composite they had begun incorporating into the interior elements of Polestar vehicles.
The aim of his thesis was to explore and comprehend the fundamental elements of a brand’s design language, focusing on balance, silhouette, and CMF (colour, material, finish) to establish a brand identity. This interplay of materials, colors, proportions, and “stance” (such as the vehicle’s height and its relationship to the ground) is vital in shaping these perceptions. While at Konstfack, he has concentrated on expanding his expertise in CAD and design to enhance his background as a craftsman and vehicle builder/renovator.
Exoskeleton design
Joel: “I looked into current electric motorcycles and noticed that many are built with a steel frame that has separate boxes for the batteries, motor, and fairings”. That sparked an idea: “Could I create a chassis that also serves as an integrated container for these components?”
Joel explains, “I came up with a design where the whole motorcycle forms a unified ‘box,’ similar to a scorpion’s exoskeleton, with all the components fitting seamlessly together.”
It enables:
- Eliminate both metal frame and plastic covers
- Protect the components internally
- Using biocomposite as a supporting structure
- Create greater freedom in design
The exoskeleton design introduces innovative opportunities for integrated storage solutions. By making use of the spaces within the exoskeleton, components such as batteries and engines can be securely stored, offering riders enhanced storage capacity without sacrificing design or aerodynamics. This method enables the use of bio composites to serve as both the frame and panels, thereby reducing material consumption.
Throughout the process, he has often wondered if he has taken on too many elements to explore in such a limited timeframe. However, the various components of the project have been essential to achieving the final outcome and fulfilling his vision. In examining Polestar’s design and adapting it to the motorcycle, he faced challenges involving advanced form, color schemes, and balance. The project’s scope has been both demanding and transformative, and he has extensively used the CAD program Rhino and explored SubD.
Joel found it thrilling to explore and challenge conventional motorcycle design, always on the lookout for innovative approaches. Yet, he consistently emphasized that his ideas must be both credible and practical, a core element of his work.
Joel: “I’ve created a high-performance bio-composite exoskeleton motorcycle designed for commuting as well as road and track racing with your motorcycle club. It beautifully merges Polestar’s unique minimalist style with the bold, high-performance spirit of motorcycle culture.”
Prototype
Creating the prototype demanded hundreds of workshop hours and approximately 300 hours of 3D printing. Significant effort was invested to align the panels, ensuring the motorcycle’s structure accurately conveyed the intended expression.
To illustrate his vision and capture the emotions evoked by a motorcycle, Joel decided to construct a full-scale prototype. By incorporating real tires, high-quality paint, functioning lights, and premium components, he aimed to provide an authentic experience of his design and communicate his vision effectively. As time constraints prevented building the entire motorcycle from biocomposite, he opted to 3D print the outer shell.
The prototype’s construction began with sponsored components from Bikepart (https://bikepart.se), including wheels, a swingarm, and a frame. Patternless tires were fitted, and a front fork he already possessed was used temporarily. Since the existing frame didn’t meet the necessary specifications, Joel constructed a new one to achieve the correct dimensions and accommodate the mounting of the outer shell. The swingarm, rear shock, and fork attachments were meticulously measured and aligned using a laser, striking a balance between black details and painted surfaces.
Exhibition
For the exhibition, he constructed a 25 cm high platform to elevate the motorcycle display, creating the illusion that it was floating above the ground to convey a sense of lightness. A broad sheet of paper in the same color as the platform was hung in the background, as Joel aimed to provide an ideal setting for visitors to capture photographs during the event.
Around 3000 people attended the opening, and the reaction was incredible, with many visitors expressing their amazement and questioning whether the motorcycle was operational. Representatives from Öhlins visited and were very enthusiastic; they plan to feature the prototype in their showroom and discussed the possibility of showcasing it at a trade fair in Milan.
About Joel Wengström
Joel’s passion for vehicles blossomed after he finished high school. He pursued marine engineering, focusing on boat repair, and began working at Plastskador & Montage AB, where he dealt with boat repairs and modifications. There, he mastered working with various materials such as composites (fiberglass, carbon fiber, Kevlar), metal, wood, and paint. Having access to a range of materials, machinery, and facilities was a great benefit, enabling him to work on personal projects during his free time.
At 25, Joel purchased his first motorcycle. After a few rides, he took it apart and transformed it into a café racer, drawing inspiration from 1950s England, where “leatherheads” raced between local cafés on their customized bikes. Joel has always been intrigued by the process of rebuilding and enhancing vehicles, which motivated him to acquire various skills necessary to bring his design concepts to life.
