We may not have been involved in the initial design before the tooling was cut, but the design changes implemented transformed this project into a robust plastic injection molded brick house. These changes utilized all necessary design techniques from both internal and external plumbing assembly, to brass inserts for secure fastener strategies. The plumbing, constructed from strengthened, glass-filled PA6 for increased durability, alongside the exterior ASA shell with additives to reduce discoloration and cracking from prolonged sun and salt exposure, demonstrates optimized material selection for this application. The draft angles were modified to a minimum 0.5 degree to facilitate smooth mold cavity extraction, while ribs were incorporated to enhance strength, maintaining nearly the same thickness as the parent material to mitigate unsightly deformation from shrinkage. An integral part of the rigorous validation process was assessing failure torques, especially when perfecting seals to prevent leaks. A few components, like the hose intake, initially failed at the identified red line. However, significant investment and effort from the SeaMule team ensured that failure was virtually eliminated during both the usage and construction phases. This outboard flushing unit truly stands as a BRICK HOUSE in design and functionality.
