Sports Nutrition Dispenser Prototype Design
Budget: £250 – £750 GBP
Product Design and CAD for Prototype Manufacture (Vacuum Casting and 3D Printing)
Project Overview
We are a UK-based low-volume manufacturing company looking for an mechanical product designer / CAD engineer to support the prototype development of a reusable sports nutrition dispensing device.
This project is manufacture-led, not conceptual. Prototypes will be produced in-house using vacuum casting, SLA and FDM 3D printing, and the design must be created specifically around these processes.
Project Objective
To deliver a manufacture-aware CAD design suitable for functional prototyping, testing and iterative refinement, with correct tolerances, materials and assembly strategies from the outset.
Branding and visual styling are not the focus of this phase.
Manufacturing Processes (Must Be Designed For)
The final design must be compatible with:
• Vacuum casting (silicone and rigid urethane parts)
• SLA 3D printing (fine detail, hinges, locking features, nozzle and lid)
• FDM 3D printing (early fit and form testing, jigs if required)
All tolerances, fits and assemblies must be realistic for prototype manufacture, not injection-mould perfection.
Key Design Requirements
• Reusable dispenser for standard energy gel sachets
• Controlled, multi-squeeze dispensing
• Leak-free between uses
• One-handed operation during movement
Hinge and Lid System
• Nozzle and lid operate on a hinged mechanism
• Hinge concept similar in principle to an Apple AirPods-style lid
• Smooth controlled motion with positive end stops
• Designed to be achievable via SLA printing and vacuum-cast replication
Internal Functional Systems
• Progressive compression of sachet contents
• Internal silicone interfaces to regulate flow
• Prevent burst dispensing
• Secure sachet positioning during tear and use
Locking and Closure
• Positive mechanical lock
• Clear tactile feedback
• Resistant to accidental opening
• Designed for real-world prototype tolerances
Materials (Prototype Phase)
Indicative materials, final selection to be agreed:
• Silicone or TPE for internal grip and compression parts
• Urethane or rigid resin equivalents for shell components
• Printed resin parts for hinges and nozzle
Required Deliverables
CAD Output
• Fully detailed CAD design
• STEP files for all parts and assemblies
Silicone Tooling
For all silicone or elastomeric parts:
• Separate CAD for each cast component
• Matching 3D-printable mould designs for vacuum casting
• Moulds must include:
• Correct parting lines
• Vent holes for air release
• Suitable wall thickness for printed moulds
• Alignment features where required
Manufacturing Detail
• Tolerances suitable for SLA, FDM and vacuum casting
• Notes on critical fits and interfaces
Required Experience
• Mechanical product design
• CAD for prototyping and low-volume manufacture
• Vacuum casting and elastomer design
• 3D printing constraints (SLA and FDM)
This is not a branding or concept-only project.
Additional Notes
• Sensitive product details will be shared after engagement
• Further prototype and refinement phases may follow
Project Overview
We are a UK-based low-volume manufacturing company looking for an mechanical product designer / CAD engineer to support the prototype development of a reusable sports nutrition dispensing device.
This project is manufacture-led, not conceptual. Prototypes will be produced in-house using vacuum casting, SLA and FDM 3D printing, and the design must be created specifically around these processes.
Project Objective
To deliver a manufacture-aware CAD design suitable for functional prototyping, testing and iterative refinement, with correct tolerances, materials and assembly strategies from the outset.
Branding and visual styling are not the focus of this phase.
Manufacturing Processes (Must Be Designed For)
The final design must be compatible with:
• Vacuum casting (silicone and rigid urethane parts)
• SLA 3D printing (fine detail, hinges, locking features, nozzle and lid)
• FDM 3D printing (early fit and form testing, jigs if required)
All tolerances, fits and assemblies must be realistic for prototype manufacture, not injection-mould perfection.
Key Design Requirements
• Reusable dispenser for standard energy gel sachets
• Controlled, multi-squeeze dispensing
• Leak-free between uses
• One-handed operation during movement
Hinge and Lid System
• Nozzle and lid operate on a hinged mechanism
• Hinge concept similar in principle to an Apple AirPods-style lid
• Smooth controlled motion with positive end stops
• Designed to be achievable via SLA printing and vacuum-cast replication
Internal Functional Systems
• Progressive compression of sachet contents
• Internal silicone interfaces to regulate flow
• Prevent burst dispensing
• Secure sachet positioning during tear and use
Locking and Closure
• Positive mechanical lock
• Clear tactile feedback
• Resistant to accidental opening
• Designed for real-world prototype tolerances
Materials (Prototype Phase)
Indicative materials, final selection to be agreed:
• Silicone or TPE for internal grip and compression parts
• Urethane or rigid resin equivalents for shell components
• Printed resin parts for hinges and nozzle
Required Deliverables
CAD Output
• Fully detailed CAD design
• STEP files for all parts and assemblies
Silicone Tooling
For all silicone or elastomeric parts:
• Separate CAD for each cast component
• Matching 3D-printable mould designs for vacuum casting
• Moulds must include:
• Correct parting lines
• Vent holes for air release
• Suitable wall thickness for printed moulds
• Alignment features where required
Manufacturing Detail
• Tolerances suitable for SLA, FDM and vacuum casting
• Notes on critical fits and interfaces
Required Experience
• Mechanical product design
• CAD for prototyping and low-volume manufacture
• Vacuum casting and elastomer design
• 3D printing constraints (SLA and FDM)
This is not a branding or concept-only project.
Additional Notes
• Sensitive product details will be shared after engagement
• Further prototype and refinement phases may follow