Automotive Coolant Expansion Tank Design
Budget: $250 – $750 USD
Project Description:
We are seeking an experienced Product Design Engineer to develop a final,production-ready design for an automotive coolant expansion tank. The key requirement is that the tank must be manufactured using a hot melt (or hot plate) welding process to join two halves.
We have an initial 3D concept that requires refinement for product performance, manufacturability, and assembly. The successful freelancer will be an expert in DFM (Design for Manufacturing) specifically for plastic welding processes and pressure vessel applications.
Key Objectives:
1. Refine our initial 3D concept into a final, functional, and manufacturable design.
2. Ensure product performance for its application (handling coolant under pressure and vacuum).
3. Optimize the design for the hot melt welding process to ensure high yield and strength in production.
Scope of Work:
The selected freelancer will be responsible for the following tasks:
Phase 1: Design Analysis & Feasibility
· Review the provided initial 3D concept and project brief.
· Perform a preliminary DFM analysis, focusing on the hot plate welding process.
· Identify potential issues related to material selection, wall thickness, weld joint design, and structural integrity.
Phase 2: Detailed Product Design & Engineering
· Redesign the tank for optimal performance, including:
· Strength & Durability: Ensure the tank can withstand specified internal pressure and vacuum cycles without failure.
· Fluid Dynamics: Optimize the internal baffling (if any) to prevent sloshing and ensure proper coolant de-aeration.
· Port & Connection Design: Design all inlet, outlet, and pressure cap threads to meet industry standards.
· Mounting Features: Integrate robust and vibration-resistant mounting points.
· Select a suitable plastic material (e.g., PA66-GF30, PP) compatible with hot melt welding and automotive coolant.
Phase 3: Design for Manufacturability (Hot Melt Welding)
· Weld Joint Design: Engineer the mating surfaces of the two tank halves specifically for hot plate welding. This includes defining the geometry (e.g., tongue-and-groove, shear joint) to ensure a strong, leak-proof seal.
· Flash Trap Design: Design the part to control melted plastic flash (overflow) in a way that it does not interfere with function or appearance.
· Tolerance Analysis: Define critical tolerances for the weld surfaces and overall part dimensions.
· Draft Angles & Moldability: Ensure all features have appropriate draft and can be easily ejected from an injection mold (as the two halves will be molded separately).
Deliverables:
Upon completion, you will provide the following:
1. Final 3D CAD Model: A fully detailed model in a neutral format (e.g., STEP, IGES) and the native CAD format (please specify your software).
2. 2D Engineering Drawings: Comprehensive drawings including all critical dimensions, GD&T (Geometric Dimensioning and Tolerancing), weld joint specifications, and material callouts.
3. DFM Report: A summary document explaining the design choices made for manufacturability, specifically for the hot melt process, and how they address potential production challenges.
4. Bill of Materials (BOM): A list of all components, including the recommended plastic resin grade.
Required Skills and Experience:
· Must Have:
· Proven experience in product design of plastic fluid containers or pressure vessels.
· Expert knowledge of Design for Manufacturing (DFM) for plastic injection molding.
· Specific, demonstrable experience with hot plate / hot melt welding design. Please provide examples in your proposal.
· Proficiency in CAD software (e.g., SolidWorks, CATIA, Siemens NX).
· Strong understanding of GD&T.
· Nice to Have:
· Experience in the automotive industry.
· Knowledge of FEA (Finite Element Analysis) for stress analysis.
· Understanding of SAE/USCAR standards for coolant systems.
How to Apply / Proposal Requirements:
To be considered, please submit a proposal that includes:
1. Your fixed-price bid for the entire project.
2. Your estimated timeline for completion.
3. Examples of past work that are directly relevant to plastic welded part design. Links to portfolios are welcome.
4. A brief description of your approach to this project, specifically how you would design the weld joint for the hot melt process.
5. Any initial questions you have about our concept.
Preference will be given to freelancers who can demonstrate specific experience with hot melt welding design.
We look forward to working with a skilled professional to bring this product to life.
We are seeking an experienced Product Design Engineer to develop a final,production-ready design for an automotive coolant expansion tank. The key requirement is that the tank must be manufactured using a hot melt (or hot plate) welding process to join two halves.
We have an initial 3D concept that requires refinement for product performance, manufacturability, and assembly. The successful freelancer will be an expert in DFM (Design for Manufacturing) specifically for plastic welding processes and pressure vessel applications.
Key Objectives:
1. Refine our initial 3D concept into a final, functional, and manufacturable design.
2. Ensure product performance for its application (handling coolant under pressure and vacuum).
3. Optimize the design for the hot melt welding process to ensure high yield and strength in production.
Scope of Work:
The selected freelancer will be responsible for the following tasks:
Phase 1: Design Analysis & Feasibility
· Review the provided initial 3D concept and project brief.
· Perform a preliminary DFM analysis, focusing on the hot plate welding process.
· Identify potential issues related to material selection, wall thickness, weld joint design, and structural integrity.
Phase 2: Detailed Product Design & Engineering
· Redesign the tank for optimal performance, including:
· Strength & Durability: Ensure the tank can withstand specified internal pressure and vacuum cycles without failure.
· Fluid Dynamics: Optimize the internal baffling (if any) to prevent sloshing and ensure proper coolant de-aeration.
· Port & Connection Design: Design all inlet, outlet, and pressure cap threads to meet industry standards.
· Mounting Features: Integrate robust and vibration-resistant mounting points.
· Select a suitable plastic material (e.g., PA66-GF30, PP) compatible with hot melt welding and automotive coolant.
Phase 3: Design for Manufacturability (Hot Melt Welding)
· Weld Joint Design: Engineer the mating surfaces of the two tank halves specifically for hot plate welding. This includes defining the geometry (e.g., tongue-and-groove, shear joint) to ensure a strong, leak-proof seal.
· Flash Trap Design: Design the part to control melted plastic flash (overflow) in a way that it does not interfere with function or appearance.
· Tolerance Analysis: Define critical tolerances for the weld surfaces and overall part dimensions.
· Draft Angles & Moldability: Ensure all features have appropriate draft and can be easily ejected from an injection mold (as the two halves will be molded separately).
Deliverables:
Upon completion, you will provide the following:
1. Final 3D CAD Model: A fully detailed model in a neutral format (e.g., STEP, IGES) and the native CAD format (please specify your software).
2. 2D Engineering Drawings: Comprehensive drawings including all critical dimensions, GD&T (Geometric Dimensioning and Tolerancing), weld joint specifications, and material callouts.
3. DFM Report: A summary document explaining the design choices made for manufacturability, specifically for the hot melt process, and how they address potential production challenges.
4. Bill of Materials (BOM): A list of all components, including the recommended plastic resin grade.
Required Skills and Experience:
· Must Have:
· Proven experience in product design of plastic fluid containers or pressure vessels.
· Expert knowledge of Design for Manufacturing (DFM) for plastic injection molding.
· Specific, demonstrable experience with hot plate / hot melt welding design. Please provide examples in your proposal.
· Proficiency in CAD software (e.g., SolidWorks, CATIA, Siemens NX).
· Strong understanding of GD&T.
· Nice to Have:
· Experience in the automotive industry.
· Knowledge of FEA (Finite Element Analysis) for stress analysis.
· Understanding of SAE/USCAR standards for coolant systems.
How to Apply / Proposal Requirements:
To be considered, please submit a proposal that includes:
1. Your fixed-price bid for the entire project.
2. Your estimated timeline for completion.
3. Examples of past work that are directly relevant to plastic welded part design. Links to portfolios are welcome.
4. A brief description of your approach to this project, specifically how you would design the weld joint for the hot melt process.
5. Any initial questions you have about our concept.
Preference will be given to freelancers who can demonstrate specific experience with hot melt welding design.
We look forward to working with a skilled professional to bring this product to life.