IP67 Certified Plastic Enclosure Redesign

About the project

Project Title: Scan-to-CAD Plastic Enclosure Redesign: IP67 Tongue-and-Groove Seal & Screw Boss Optimization (ICAT Compliance) Project Overview: We have high-resolution 3D scan data of an automotive/industrial plastic enclosure assembly that requires conversion into a parametric, injection-moldable CAD solid model (STEP/native CAD). The outer physical boundary dimensions must remain completely unchanged, as the external form factor is already homologated/approved by ICAT. Your task is to re-engineer the internal split-line, sealing interface, and fastening features to achieve certified IP67 ingress protection while maintaining current injection molding cycle times and cost targets. Scope of Work & Technical Requirements 1) Scan-to-CAD Parametric Reconstruction: 1.1) Reconstruct clean, parametric B-Rep CAD solids (STEP AP214/AP242 + native CAD) from provided scan data. 1.2) Preserve all critical external envelope dimensions and mounting interfaces exactly. 1.3) Maintain consistent nominal wall thicknesses with proper tool draw/draft angles throughout. 2) IP67 Tongue-and-Groove Perimeter Redesign: 2.1) Design a precision tongue-and-groove perimeter channel tailored for an elastomeric O-ring / continuous gasket seal capable of passing IP67 immersion tests (1 meter depth for 30 minutes). 2.2) Specify exact groove width, depth, draft, and corner bend radii to achieve proper volumetric fill (75%–85%) and target compression (20%–28%) without pinching or rolling. 2.3) Incorporate external mechanical hard stops (landings) to prevent over-compression and define a positive travel limit. 3) Screw Boss Engineering (Self-Tapping Screws Only): 3.1) No brass/heat-set inserts: The design must use direct thread-forming/self-tapping screws (e.g., PT/EJOT style) to avoid post-molding operations, cycle-time penalties, and secondary component costs. 3.2) Size the boss core hole diameters, counterbores, and outer boss diameters strictly according to plastic resin guidelines to prevent hoop-stress cracking, boss bursting, or stripping. 3.3) Add structural gussets to all bosses to prevent wall deflection and bowing between fastener locations under gasket reaction loads. 3.4) Ensure screw bosses sit strictly outside the primary O-ring sealing boundary. 4) DFM & Moldability Verification: 4.1) Ensure uniform parting lines, shut-offs, and draft angles (0.5degree to 1.0degree inside seal grooves). 4.2) Identify and eliminate sink marks or heavy mass concentrations behind screw bosses and ribs. Deliverables Required: Fully parametric 3D CAD model files (.STEP, .IGES, and native format such as SolidWorks / Creo / NX). Cross-sectional 2D engineering drawing (.PDF / .DWG) detailing the O-ring groove, tongue interface tolerances, and screw boss geometry. Brief technical summary document defining: Recommended O-ring cord cross-section and material hardness (Shore A). Recommended self-tapping screw specification (thread size, pitch, and pilot hole dimensions). Fastener tightening torque recommendation. Freelancer Requirements & Experience: Proven track record in plastic injection molding design and DFM. Demonstrated experience designing enclosures that successfully achieved certified IP67/IP68 ingress protection. Strong expertise in scan-to-CAD reverse engineering. Portfolio/examples of similar plastic enclosure and sealing projects are mandatory with your bid.

Skills required