The XP2260 launched in 2010 as the premium jump starter. I modeled the concept and production CAD including the separate front cover, PVC base, and soft touch handle components.
Packaging of all the components required several rounds of prototyping to insure proper fit, airflow, and heat management.
The SJ1 is an updated XP2260. The exterior shape was modified several times during development as specifications changed. Customer feedback led to a more prominent ON/OFF knob.
The XP750C, a midlevel product, was modeled to accept several battery sizes, giving a flexible price point.
Schumacher's jump starters for DieHard have similar features in unique enclosures.
The XC75 charger required uniquely designed fastening features for the interface panel, handle, and top to bottom cover attachment.
The SC8 charger, a restyled XC75, refined the attachment between the interface and top cover to simplify assembly and increase impact resistance.
The XCS15 charger has integrated cable management and discreet cooling openings.
The SC4 charger updated the XCS15 with a prominent ON/OFF switch designed into the top cover with a living hinge under the faceplate label.
The SC10 charger's metal enclosure has ventilation that meets UL requirements and a plastic insert on top for carrying the unit.
The SC3 charger's overmolding protects the unit from drop damage and was fun to model in 3D.
The XI75 inverter carried the beveled design language from the XP and XC units.
The SI1 inverter features a swivel neck and carefully designed cooling vents. Packaging inverter components requires close management of shapes and air volumes to avoid exceeding exterior surface temperature limits.
The SI4 inverter added a second AC and USB port on a remote extension cable for front and back seat use in vehicle.
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Schumacher Electric Products
These are some of the jump starters, chargers, and inverters I modeled at Schumacher Electric. For some products I created the first 3D CAD; for others I turned initial CAD into production-ready shapes that met packaging, impact, and molding requirements. On many I created backside internal features such as mounting bosses and ribs. Initial concepts were generated by Design Integrity.
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