MaxFlow Filters had an established reputation and product line catering to professional chainsaws, but the legacy filter systems relied on older mechanical designs and lacked detailed CAD documentation suitable for refinement, supplier handoff, and future product evolution.

At the start, the core product concept — a high-flow, oiled foam air filter — had proven field performance and patents, yet required modernized, CAD-based engineering to support manufacturing consistency and product iterations. The challenge was to preserve the performance advantages and brand recognition while translating the design into structured, manufacturable CAD for production and product expansions.

I developed a clean, production-ready mechanical definition of the MaxFlow filtration system that could be consistently manufactured and scaled, while honoring the performance and functional legacy of the product.

My contribution included:
• Mechanical systemization of the patented filter design with detailed parametric CAD
• Defining internal cage geometry and sealed endwall features for maximum performance
• Optimizing wall thickness, draft, and foam retention elements for repeatable manufacturing
• Clearly documenting fitting interfaces for various Stihl chainsaw models
• Structuring CAD for supplier use and future product versions

This work preserved all known performance advantages — including high airflow, foam stability, and sealing integrity — while ensuring the design assets were engineered for long-term production and quality control.