Automotive Fuel Filler System

The role of the fuel filler within a vehicle is to enable the safe conveyance of fuel from the fuel nozzle to the fuel tank. As stricter emission laws are being put into place, the demand for lightweight and fuel efficient vehicles increases, therefore meaning the weight of the components within the vehicle must decrease. The aim of this project was to provide a new light weight design solution for a specific fuel filler manufactured at Unipart. The goal was to provide a 20% weight saving through an improved design of the fuel filler. The project and design proposed achieved an overall weight saving of 30% through design changes to the flange, brackets, rubber hose and filler pipe of the fuel filler. This was all redesigned and weight savings were calculated through the use of CATIA V5.