Estarli Cycle Systems is a benchmark in the world of electric bikes; renowned for its impeccable engineering and commitment to quality

Estarli Cycle Systems refers to the electrical components, software and batteries in our bikes that interconnect to give you the boost you need, every day. Each system is meticulously designed to the bike to ensure optimal performance, efficiency, and longevity, meeting the needs of even the most demanding riders. This attention to detail extends to every component within the system; reflecting our philosophy of precision and innovation which we believe sets us apart.

One of the most remarkable aspects of Estarli Cycle Systems is its reliability - demonstrated by a failure rate of just 0.01%. With over 10,000 bikes on the road, the numbers speak for themselves. Our riders trust our electrical systems for seamless performance, whatever the environment. This near-flawless track record underscores our commitment to excellence and our dedication to providing a worry-free cycling experience for every customer.

Each system is engineered to fit the unique functions of each e-bike model. It’s this synergy between hardware and software that creates the special Estarli sauce. We tailor and optimise the sensors and motor in your bike to deliver the power when you need it, in the way you need it. This is why our bikes feel so natural and intuitive to ride - all the way from the smallest folder to a cargo with a heavy load. 

We adopt an open-source system which allows our e-bikes to be monitored, checked and re-programmed up and down the country by trained bike mechanics. Similarly, backward compatibility is always kept in mind to ensure your e-bike never becomes outdated. When we develop new technology, in most cases you can upgrade or replace parts of your Estarli System should you wish.

Computer Tests
We begin with computer-aided design, strength and durability simulations to ensure all systems are robust and ready for production.

Lab Tests

Once samples are created, they undergo a rigorous series of tests designed to push the limits well beyond real-world conditions. These include:

• Water penetration
• Saltwater exposure
• Humidity simulation
• Extreme temperature (high and low)
• Vibration testing
• High-frequency sound wave testing

Our Battery Management System (BMS) is specifically tested for heat resistance, short circuit resilience, and current flow monitoring.

Real-World Tests
The Estarli R&D team conducts extensive prototype testing across the Chiltern Hills, focusing on:

• Hill climbing under load
• Repeated folding and unfolding
• Trail and cross country riding
• Longevity and usability testing (school runs, commutes & train journeys)
  

In parallel, selected retail partners carry out independent real-world testing under varied conditions.

Test-Driven Production
Each unit is run through every stage of our production line. A bike only advances once all tests at each station are completed and passed — ensuring consistent quality from start to finish.

LEAN Engineering
Post-launch, we operate a continuous improvement programme. Feedback from our customers and retail partners feeds directly into our engineering process, helping us refine each model and system continually.