3D Solidworks CAD files +DFM +FEM - Medical device assembly

Project Overview We are developing a disposable single-use medical device currently prototyped using 3D printed parts. The assembly consists of: 6 custom plastic parts 2 off-the-shelf components Functional clips and snap-fit features Existing SolidWorks CAD files Existing functional prototype The objective is to convert the current prototype into an injection-moldable design while preserving the existing architecture and functionality as much as possible. The product is intended for future pilot production and high-volume manufacturing. This is not a cosmetic redesign project. We are looking for an experienced Product Design Engineer capable of transforming a prototype into a robust, manufacturable and cost-effective product. Scope of Work Phase 1 – Design Review Review the complete assembly and all custom parts. Identify: DFM issues Assembly risks Snap-fit and clip risks Injection molding challenges Opportunities for cost reduction Opportunities for material optimization Deliverables: Design review report DFM assessment Risk assessment Recommended modifications Preliminary material recommendations Phase 2 – CAD Redesign Modify the existing design to make it suitable for injection molding. Tasks may include: Draft angles Wall thickness optimization Rib design Boss design Snap-fit optimization Undercut reduction Assembly improvements Tolerance recommendations Deliverables: Updated SolidWorks part files Updated SolidWorks assembly Design change log Design rationale Phase 3 – Engineering Validation Perform engineering analysis where required. Examples: Snap-fit analysis Clip deflection analysis Stress analysis Assembly force estimation Material comparison Deliverables: FEM / FEA reports Design recommendations Risk mitigation recommendations Phase 4 – Manufacturing Readiness Prepare the design for tooling review and pilot production. Deliverables: Production-ready CAD files Toolmaker package Manufacturing recommendations Moldability review Required Skills Product Design Engineering Mechanical product design Plastic product development Assembly design High-volume consumer or medical products SolidWorks SolidWorks Professional or Premium Native SolidWorks deliverables required Fully editable feature tree required Injection Molding Strong experience with: DFM DFA Draft angles Parting lines Gate locations Wall thickness optimization Ribs Bosses Snap-fits Clips Retention features Undercuts Shrinkage considerations Engineering Analysis Experience with: FEM / FEA Snap-fit analysis Plastic deformation analysis Stress analysis Materials Experience selecting plastic materials such as: Polycarbonate (PC) Medical PC Copolyester PETG ABS PP POM TOPAS COC Other suitable medical-grade materials Current Status The product already exists as: Working prototype Existing CAD assembly Existing SolidWorks files The objective is not to redesign the product from scratch. The objective is to maintain the existing concept while making it suitable for injection molding and future manufacturing. Experience Required Please provide examples of: Plastic Parts Examples including: Snap-fits Clips Retention features Injection-molded assemblies Product Development Examples where you: Converted prototypes into production parts Optimized parts for injection molding Worked directly with mold makers Medical Device Experience (Preferred) Examples involving: Medical devices Drug delivery devices Diagnostics Disposable products Wearables Ideal Freelancer Profile Experience 10+ years of product design engineering experience Strong experience with injection-molded plastic parts Experience converting prototypes into production-ready molded components Medical device experience strongly preferred Strong DFM/DFA skills Strong SolidWorks skills Practical experience working with mold makers and injection molding suppliers Experience with snap-fits, clips, retention mechanisms and plastic assemblies Ability to perform or review FEM/FEA analysis Experience selecting plastic materials for high-volume production Preferred Background Experience in one or more of the following: Medical devices Drug delivery devices Wearables Diagnostics Consumer products Industrial products manufactured by injection molding Disposable products High-volume plastic assemblies Must Be Able To Review existing CAD files and identify manufacturability risks Propose practical design improvements Deliver editable native SolidWorks files Communicate directly with tooling and molding suppliers Support design iterations quickly Provide clear engineering documentation Not Suitable For This Project Pure industrial designers CAD drafters without engineering experience Mold designers without product design experience Mechanical engineers without plastics expertise Freelancers unable to provide examples of molded plastic products Freelancers without experience taking products from prototype to manufacturing Application Questions Please answer the following: How many years of experience do you have with injection-molded plastic products? How many medical device projects have you completed? Which CAD software do you use? Which FEM/FEA software do you use? Have you designed snap-fits and clips? Please provide examples. Have you worked directly with mold makers and injection molding suppliers? Have you selected plastic materials for medical devices or disposable products? Can you provide examples of products that progressed from prototype to production? What is your hourly rate? What is your availability over the next 3 months?