Custom Aluminum BBQ Design

Job Brief: Product Design Engineer

• Gas BBQ Technical Development

Project Overview We have completed the visual design for a premium outdoor gas BBQ featuring a cast aluminium housing. We now require a Product Design Engineer to handle the mechanical and thermal engineering necessary to move from a visual concept to a production-ready prototype.

Scope of Work

1. Technical Engineering: Adapt the existing visual 3D model into a functional mechanical assembly.
2. Thermal & Airflow Management:

• Design the internal airflow system to support "oven-style" convection cooking with the lid closed.
• Engineering of the "firebox" to ensure proper oxygen mix and prevent CO accumulation.
• Design of the exhaust/venting system to maintain temperature stability while protecting against wind blow-outs (per EN 498).

1. DFM (Design for Manufacturing):

• Optimise the aluminium housing for Sand Casting (prototyping) and Die Casting (mass production).
• Define wall thicknesses, draft angles, and structural ribbing.

1. Gas Train Integration: Integrate a pre-certified gas system (valve, manifold, burner) from a supplier (e.g., Copreci). Ensure safe clearances between burners and the aluminum body to prevent overheating of external surfaces.

Technical Requirements

• Gas Expertise: Deep understanding of the Venturi effect, burner port loading, and flame stability.
• Oven Dynamics: Proven experience in deg lid-down cooking systems (airflow, heat retention, and grease management).
• Software: Mastery of SolidWorks, Fusion 360, or Catia (standard for foundry communication).
• Standards: Knowledge of EU 2016/426 (GAR) and EN 498 to ensure the design is "certifiable" by bodies like Certigaz.

Key Deliverables

• Production-Ready CAD (STEP/Native): Including all internal mounts, hinges, and sealing points.
• Thermal Strategy Doc: Briefing on how the design manages heat to protect the user and the paint finish.
• BOM (Bill of Materials): Specification of fixings, gaskets, and gas components.

Budget is TBC, please detail your price for the project. Budget: EUR 1500–3000 Skills: CAD/CAM, Solidworks, Mechanical Engineering, Manufacturing Design, Product Design, DFM (Design for Manufacturing), Fusion 360, Manufacturing Engineering