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Project Title: Mechanical Validation & Prototyping: 60GHz RF Optic Enclosure (ULTEM™) Project Overview We are seeking a Senior Mechanical Development Engineer to move a patented RF-enhancement technology—the RF BENDER™—from simulation to physical benchmarking. The core of the project involves designing and testing a monolithic lens/housing assembly for 60GHz mmWave radar sensors. This product targets both the Automotive (Child Presence Detection) and Commercial Real Estate (Smart HVAC/Lighting) markets. The Challenge The "product" is a refractive lens that provides a 12dBi signal gain. Because we are working at 60GHz (millimeter wave), the physics is unforgiving. A deviation of 0.1mm in geometry will result in signal failure. We need an engineer who can treat plastic as a precision optical component. Key Responsibilities 1. Monolithic Design (CAD): Integrate a 2.84mm refractive datum with a snap-fit housing for a PCB. The design must maintain a strict 3.0mm air gap between the chip and the lens. 2. Material Strategy: Optimize the design for ULTEM™ 1010/9085 (PEI) to ensure thermal stability and dielectric consistency. 3. Physical Benchmarking: * Design a non-reflective, rigid test jig. • Execute range-extension and "punch-through" tests using radar visualizer software. • Validate the 12dBi gain theory through empirical data. 4. DFM (Design for Manufacturing): Prepare files for high-temp injection molding with specific attention to Tolerance Stack-up Analysis. Required Skill Levels & Tools • Software: SolidWorks Professional (Simulation/Flow), Geomagic (for 3D scanning/automotive integration). • Precision: Mastery of GD&T with a track record of holding +/- 0.05mm tolerances in high-performance polymers. • V&V Experience: Ability to write a formal Validation Report for investors. Experience in the Medical Device (ISO 13485) or Aerospace sectors is highly preferred. Why Join This Project? • Foundation of Equality: We are democratizing life-safety tech. Our goal is a $99 installed price point to ensure "Warfighter-grade" safety is accessible to all. • Veteran-Led: This is a mission-driven project led by a disabled war veteran and commercial developer. • Clear Exit Path: This validation phase is the final step before we trigger our Royalty-Based (Royal Position) funding and move to mass production. Candidate Instructions Please provide a brief summary of your experience with high-temp polymers (ULTEM/PEEK) and any experience you have with RF packaging or precision optical enclosures. If you have access to high-end metrology (CMM/3D Scanning), please highlight this in your proposal.
Projekt-ID: 40261166
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14 freelancere byder i gennemsnit $81 USD/time på dette job

I am a Senior Mechanical–Electronics Development Engineer with experience delivering precision polymer assemblies for high-frequency electronic systems, including tight-tolerance PCB–enclosure integrations. I have worked with high-temperature polymers such as ULTEM 1010, ULTEM 9085, and PEEK in applications requiring thermal stability, dielectric consistency, and ±0.05 mm tolerance control. My background includes RF-aware enclosure design for mmWave electronics, controlled air-gap validation, and GD&T-driven tolerance stack-up analysis for injection molding. I use SolidWorks Professional (Simulation/Flow) for monolithic snap-fit structures and thermal deformation studies, ensuring dimensional stability at 60 GHz-critical geometries. For validation, I design rigid, non-reflective jigs and execute empirical benchmarking, correlating gain performance against simulation models. I have access to CMM and industrial 3D scanning for metrology verification and reverse validation before tooling release. I can deliver production-ready DFM files and a formal validation report suitable for investor review and pre-mass-production approval.
$83 USD på 40 dage
5,9
5,9

Hello Sir as i am control engineer and i have master degree i can solve this using LabVIEW as i am certified architect in it so that would be easy for me to fulfill all your requirements , thanks
$83 USD på 40 dage
4,1
4,1

I am a seasoned Mechanical Development Engineer with extensive experience in working with high-temp polymers, specifically ULTEM and PEEK. My strong background in designing precision optical components for high-frequency applications, coupled with extensive proficiency in SolidWorks and GD&T, ensures the highest level of accuracy down to +/- 0.05mm tolerances. Additionally, I have a solid track record of developing RF packaging solutions and conducting rigorous physical benchmarks in line with validation requirements, reinforcing reliability and performance. Joining your mission-driven team to democratize life-safety tech is an opportunity I am eager to pursue.
$83 USD på 40 dage
2,8
2,8

Hi there, I am excited about the opportunity to work on the RF BENDER™ project as a Senior Mechanical Development Engineer. My extensive experience with high-temp polymers, particularly ULTEM and PEEK, positions me perfectly to help design and prototype the critical refractive lens for your 60GHz mmWave sensors. With a track record of mastering GD&T and achieving tolerances within +/- 0.05mm, I understand the unforgiving nature of precision in this realm. I have successfully executed projects involving high-performance polymers and have practical experience creating designs ready for high-temp injection molding. I also have access to high-end metrology tools, including CMM and 3D scanning, which can further ensure the precision required for signal optimization. I believe I can effectively address the challenges of your project while aligning with your mission-driven objective to provide affordable life-safety tech. Please message me to discuss the next steps and share your insights about the project's timeline and requirements. What specific challenges have you encountered in past projects when dealing with millimeter wave technologies?
$75 USD på 36 dage
0,0
0,0

Hello, We’ve thoroughly reviewed your project details and are excited about the opportunity to contribute to the Mechanical Validation & Prototyping of the RF BENDER™. Understanding the precision required for designing a monolithic lens/housing assembly for 60GHz mmWave radar sensors, we recognize the critical importance of accuracy in achieving a 12dBi signal gain. In a previous project, we successfully transitioned a high-precision optical component from simulation to physical testing, ensuring sub-millimeter tolerances and robust material strategies, very similar to the challenges presented here. With over 8 years of experience in engineering and a record of top-rated results, our expertise in CAD design, high-temp polymer optimization, and precision engineering aligns perfectly with your project's needs. Our proficiency with SolidWorks, Geomagic, and GD&T ensures we can meet and exceed your expectations for accuracy and quality. We're eager to explore how our skills can enhance your project's success. Please message us with more details, and we will deliver a detailed, tailored proposal within 24 hours. Looking forward to collaborating on this impactful project. Best regards, Puru Gupta
$90 USD på 40 dage
0,0
0,0

With over a decade of experience in web and mobile development, I understand the critical need for precision and accuracy in your Mechanical Validation & Prototyping project. The challenge of designing a monolithic lens/housing assembly for 60GHz mmWave radar sensors is one that requires expertise and finesse. I am confident in my ability to treat plastic as a precision optical component, ensuring a 12dBi signal gain with meticulous attention to detail. My past projects in industries like HealthTech and FinTech have honed my skills in working with high-performance polymers like ULTEM/PEEK. I have a proven track record of holding tight tolerances and optimizing designs for thermal stability and consistent dielectric properties. My experience in V&V reporting aligns with your requirement for a formal Validation Report, showcasing my ability to deliver results that meet industry standards. I am excited about the opportunity to work on this groundbreaking project with you. If you are interested in collaborating, please reach out to discuss further details.
$90 USD på 15 dage
0,0
0,0

I'm thrilled about the opportunity to collaborate with you on the Mechanical Validation & Prototyping project for the 60GHz RF Optic Enclosure. With my strong background in engineering and precision optical components, I'm well-equipped to meet your needs. I have significant experience in CAD design (SolidWorks Professional) and expertise in high-performance polymers like ULTEM™. By ensuring meticulous attention to detail and adherence to strict tolerances, I am confident in delivering top-notch results. Your project's innovation and impactful applications drive this passion of mine, and I look forward to the possibility of working together. Rest assured, your project will receive my utmost dedication and expertise. Thank you for considering my proposal. Regards, Jason McLachlan
$75 USD på 3 dage
0,0
0,0

Memphis, United States
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