FDM / PETG Design Optimization Engineer Needed – Improve Print Reliability of 3D printed Parts

We manufacture a modular garden bed system composed of 5 individual 3D printed components. The CAD design work is already completed and STEP files are available. The objective of this project is not to redesign the parts from scratch, but rather to review and optimize the existing designs for reliable and repeatable PETG production printing. We are currently experiencing inconsistent print quality, occasional print failures, and production variability. The parts are functional and printable, but we are looking to improve reliability, repeatability, and manufacturing robustness while maintaining the existing functionality and assembly logic. IMPORTANT: Please begin your proposal with the phrase: "Garden project" This helps us identify applicants who have read the full job description. PRINTER & MATERIAL Printer: Bambu Lab P1S with AMS Existing CAD files: STEP format Optimization recommendations should account for: PETG material behavior FDM manufacturing constraints Bambu Lab P1S capabilities Production consistency Print success rate Print orientation considerations PROJECT STRUCTURE Phase 1 – Design Audit (Milestone 1) Review the existing STEP files and identify opportunities for improvement. Deliverables: Practical audit report Prioritized list of recommended design changes Identification of: Wall thickness concerns Printability issues Support-related challenges PETG-specific concerns Potential warping risks Potential weak points Areas affecting production consistency Recommended print orientation for each part Recommended support strategy (if required) The goal is to identify improvements that increase reliability and reduce print failures. Phase 2 – CAD Optimization (Milestone 2) Modify and optimize the existing CAD designs while preserving current functionality and assembly logic. Deliverables: 5 optimized STEP files Native CAD files (Fusion 360 preferred) Summary document explaining all design changes Explanation of how each change improves printability, reliability, or manufacturing consistency The objective is not to change the product concept, but to improve production robustness. ADDITIONAL INFORMATION Shortlisted candidates will receive: Preview images of the components Photos of successful and failed prints A preliminary list of production issues observed during printing Before final selection, candidates will be asked to review these materials and confirm that the project aligns with their expertise. REQUIRED EXPERIENCE Design for Additive Manufacturing (DfAM) FDM production printing PETG optimization CAD modification and optimization Fusion 360 or equivalent CAD software Experience improving print reliability and reducing print failures Experience with Bambu Lab printers is strongly preferred. SCREENING QUESTIONS Please answer the following questions in your proposal: Question 1 Describe a 3D printed part that you redesigned specifically to improve print reliability or reduce print failures. Question 2 What are the three most common design issues you encounter when optimizing PETG parts for reliable FDM production printing? Question 3 Based on your experience, what information would you want to review before auditing an existing production part? TIMELINE Phase 1 (Audit): 10 to 15 days Phase 2 (Optimization): 10 to 15days PROJECT SETTINGS Fixed-price project Two milestones Intermediate to Expert level Less than 1 month duration Suggested milestone structure: Milestone 1 – Design Audit: 30% Milestone 2 – CAD Optimization: 70% We are looking for a practical problem-solver with real-world FDM experience, not simply a CAD designer. The ideal candidate understands how design decisions impact production consistency, print success rates, and manufacturing efficiency.