Metal Product Design Engineer for Prototype Refinement & Component Development

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Description: We are looking for an experienced product design engineer to help refine and finalize a prototype for a premium outdoor product. Key Responsibilities: Review existing CAD files and prototype details Modify and refine the design to meet updated specifications Collaborate with the inventor to brainstorm design improvements and solve engineering challenges Develop and prototype a functional and aesthetically pleasing accessory component Ensure all designs are optimized for manufacturability, durability, and ease of use Ideal Candidate: Proficient in CAD software (Fusion 360, SolidWorks, or similar) Experience with metal fabrication and heat-resistant materials Strong understanding of structural integrity and thermal management Creative problem solver with a collaborative mindset Prior experience designing consumer products, particularly in outdoor products, or similar metal-based structures, is a plus The Ember Wagon March 24, 2025 The original Ember Wagon design—though it wasn’t called that at first—was created in about half an hour ten years ago. A local welder built it based on simple drawings I had made. Over the past decade, it’s been used extensively on our Whidbey Island property and has proven to be a complete success in terms of functionality. I know it works well, and everyone who has seen it has been impressed. In 2024, Damian suggested exploring whether we could market the wagon commercially. That meant it had to be much lighter and cheaper to produce than the original prototype, which was made of 1/4-inch steel and cost around $2,500. We contacted a manufacturer and, with a lot of our input, they developed a commercially viable wagon using 1/8-inch steel. Their fancy shop built five units for us to test. These new units were the same size as the original but used 1/8-inch steel. Unfortunately, the underlying support structure proved insufficient to handle the heat. It weakened the wagon to the point where it would twist when moved. We tested it with the biggest fire we could build, using no firebricks, to see just how hot the base would get. It didn’t hold up as well as we hoped. We also created a grilling system—most of which was initially designed for the original wagon—and it worked very well. However, after using this next generation of Ember Wagons, we came up with several improvements we’d like to make. Moving Forward with the Design I’m hoping to find a designer I can collaborate with to refine the design in a practical way. Our previous designer specialized in racing parts and technical work, aiming to make the wagon as light as possible—but it almost became too light. Size Matters The most important design element is the wagon’s overall size. I felt the original design was too large for the general public, so I created a slightly smaller plywood model with the same height. That wooden prototype lasted only one fire, but it revealed several potentially good ideas (and confirmed that metal is indeed the right choice). Once the size is agreed upon, we plan to develop a number of accessories. The main two are: A screen system for sparks A grilling system A third possibility is a locking wheel system (though I’m not entirely sure it’s necessary). I have various ideas for these accessories but hope to develop even better ones in collaboration with a designer. Required Changes and Considerations Below are the specific parts we need to address: Wagon Design Fire Pan Drainage and Expansion The drainage system for the fire pan needs to accommodate heat expansion. Currently, the base pan warps under high heat. Wheel Lock System A design for locking the wheels is needed. There are a few different ways to prevent the wagon from rolling, but we haven’t settled on a solution yet. Size Adjustments If we opt for smaller proportions, the structure could change from the current design. The larger and smaller versions differ significantly. Handle Comfort Although the shape of the handle is good, it’s uncomfortable to use. We need a more ergonomic approach. Wheel/Axel Options There are two different wheel and axle possibilities worth exploring. Substructure of the Fire Pan The support framework beneath the fire pan needs improvement to prevent warping. Integration of Fire Bricks We are considering two or three possible sizes of fire bricks and how best to incorporate them. Heat-Induced Warping If we don’t change the design, the bottom will buckle under sufficient heat, causing the sides to bow out slightly, which is unacceptable. I believe there are a few simple ways to address this. Grilling System One of the Ember Wagon’s strongest points is its versatility—it’s great for general fires and also cooks very well. The grill is simple yet practical, though not perfect. There is an opportunity to combine the grilling system with the spark arrestor, though I’m not yet sure that can be done effectively. Side Bars They need to be adjusted—made a bit higher or longer—and possibly incorporate a partial spark screen. Most people would likely only use a partial screen anyway. Grill Surfaces We could offer different types. I’m most interested in custom-made 3/8-inch stainless steel bars (preferably hexagonal). Each unit would have two 12-inch grills. Another option is a pattern-cut design, which is more expensive but might appeal to some customers. Having low, medium, and high-cost options is wise. Future Roasting/Pizza Options We could explore roasting additions, such as portable pizza ovens that are already on the market. We don’t need to develop everything ourselves right away. Adjustable Grill Height It would be nice to improve the design so the grill can be placed higher above the fire. Spark Screen System In today’s world, spark screens are often required and can be costly. Our concept involves angled sides that match the Ember Wagon’s shape, surrounding all four sides with a removable top. Most of the time, the top probably won’t be used. This approach allows full spark containment when everything is in place. Without the top, it should still catch most sparks (I’d say 83%—keeping in mind 87% of statistics are made up on the spot!). Cost and Durability The spark screen might be the most expensive accessory, so we need to get it right. We’ll likely use a stainless steel solution of some kind (I have some initial ideas on this). Top Systems Roughly 97.3% of the time (see the statistic above for context), the Ember Wagon won’t be actively generating heat. How can we make it useful during that idle time? One idea is a fitted top that: Functions as an outdoor coffee table Keeps water out of the fire pit Ideally smothers the fire when placed on top, snuffing out the flames We could offer a few variations. At the very least, a waterproof fabric cover would keep rain out. Wheels We want a wheel system that’s practical, fun, and not overly expensive, possibly offering multiple options (again, low, medium, and high-end). Maybe, in the future, we could custom-source wheels—any excuse to travel abroad, right? Materials People generally want a shiny new fire pit that stays that way forever. In reality, most become rusty and eventually get thrown away. We’d love to change that, if possible. Stainless Steel Potentially cost-prohibitive, but it would be a “way cool” (colloquially speaking) high-end option if we find the right market. Rust Management Painting with heat-resistant paint, leaving it to rust naturally, scrubbing periodically, or maybe using high-heat powder coating are all considerations. I’m hoping there’s “something else” out there we haven’t yet discovered.

Keyword: 3D Modeling

Price: $65.0

3D Printing Product Development Mechanical Engineering CAD & CAM Software Problem Solving