MaxFlow Filters — High-Flow Chainsaw Air Filter System (Ongoing Product Line)

Industry:
Role & Scope:
Tools & Methods:

Key features:

  • High-flow cage + oiled foam element concept
  • System variants (MAX / MINI, Pro / Semi-Pro / Legacy)
  • Designed to fit under stock cover vs performance cover (if applicable)
  • Serviceability: access/cleaning design intent

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The Challenge:

  • Ongoing revisions across multiple models
  • Tight packaging envelope (stock cover constraints)
  • Geometry must be repeatable in fabrication (waterjet/CNC)
  • Variant accuracy matters (wrong cage/throat = wrong product)

Key constraints:

Outcome:

  • Multi-variant filter system redesign for STIHL-compatible platforms
  • Improved service interval via foam element architecture (client claim phrasing)
  • Updated covers / internal components to integrate cage/throat/element
  • Manufacturing-ready CAD support for fixtures and cutting workflows
  • Iterative refinements driven by real printing/cutting feedback

What this project demonstrates:

Process & Key decisions:

  • Variant architecture (how you kept a scalable product family)
  • Design for manufacturability (fixtures, tolerances, origin stability)
  • Iteration loop (client feedback → revised CAD → fabrication reality)

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    CAD Development & Engineering Proof: