Grill Insert Upgrade – Concealed Fastening & Structural ReinforcementBlind

in Industrial Design Services held by jonathannavarra
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Description:
Overview:
We are seeking a freelance designer to revise a plastic grill insert intended to mount into a steel bull bar. The current design suffers from poor structural rigidity and, most critically, lacks a viable fastening method along the front edge—resulting in visible warpage and an insecure fit during test fitting.

Key Issue – Front Fastening:
There is no existing mechanism to pull the leading edge of the plastic insert tightly against the steel bull bar. The final solution must incorporate a hidden front-facing fastening system (e.g. automotive-style panel moulding retainers or equivalent) that ensures a flush, secure, and rattle-free fit under vibration and load.

Fastening Method Requirements:

Must be entirely concealed once installed (no visible clips, screws, or fasteners from the front)

Must provide positive retention to pull the plastic insert snug against the steel surface

Should allow serviceability (removal and reinstallation without damage)

Steel Bar Interface:
You are not limited by the existing return surfaces of the steel bull bar. The CAD file of the opening will be provided, and you may propose modifications to any return edge or mounting surface behind the grill insert. Nothing behind the visible face is fixed—it can be adjusted to suit your fastening solution.

Project Scope Summary:

Review current CAD files of grill insert and bull bar opening

Design a complete, hidden, structurally secure fastening system

Integrate appropriate reinforcements to eliminate warpage

Modify or propose changes to steel bar geometry where necessary

Maintain the original visible aesthetics of the grill insert
Wants:
Submissions will be evaluated based on the following:

Hidden Fastening Solution

The design must use a concealed method to pull the front edge of the grill insert securely against the bull bar

No visible hardware from the front once installed

Structural Integrity

Revised design must eliminate warpage, flex, or loose fitment during real-world use

Reinforcements must be practical for injection moulding and maintain part stiffness

Compatibility with Bull Bar Geometry

Proposed solution must integrate cleanly with the provided steel bar opening

Adjustments to return surfaces are allowed and encouraged if needed for a better result

Manufacturability

Design must be suitable for production (injection moulded plastic)

Avoid unnecessary complexity or tooling challenges

Serviceability

The grill must be installable and removable without damage or excessive effort

Fastening method should support repeatable installation

Aesthetic Preservation

The outer shape and styling of the visible portion of the grill insert must remain unchanged

Any changes should be hidden or limited to non-visible surfaces

Clarity of Submission

All CAD files must be complete and properly aligned

Supporting visuals (e.g. exploded views or annotations) must clearly show fastening points and installation logic

Brief documentation explaining how the solution works, hardware used (if any), and any steel interface changes required
Don't Wants:
Conceptual or aesthetic redesigns of the visible grill insert – the outer form must remain unchanged

Fastening methods that are visible from the front or disrupt the clean face of the grill

Solutions that rely on adhesives, silicone, or unreliable clip systems not suited to off-road vibration and load

Overly complex or fragile mechanisms that complicate manufacturing or installation

Submissions that do not engage with the supplied bull bar geometry or fail to address the front-edge fastening issue

Generic models or templates not adapted to our specific part geometry and constraints
Software:
  1. 3D Solidworks

Entries

= Buyer's Rating
#25 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by Kzswara
#24 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by ArminSchehitsch
#23 Grill Insert Upgrade by sirchulle -simplest solution by sirchulle
Hidden design
#22 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by ArminSchehitsch
#21 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by Kzswara
#20 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by ArminSchehitsch
Hidden design
#19 Grill Insert Upgrade by sirchulle by sirchulle
#18 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by ArminSchehitsch
Hidden design
#16 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by sherifelsheikh
#14 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by Kzswara
#13 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by Kzswara
#12 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by Kzswara
#11 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by ArminSchehitsch
Hidden design
Download Files
#10 Syarif-Bull Bar-Grille Insert-250722 by syarifmjz
#9 Grill Insert Upgrade - Slot & Screw Method by zarwanzy
#8 Grill Insert Design Proposal by willsaltz
#7 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by sherifelsheikh
Hidden design
Download Files
#6 Plastic_Grill_slots by jokubasp
Hidden design
#5 01-Fastening by MechanicalCADdesigner
Hidden design
Download Files
#4 Grill Insert Upgrade – Concealed Fastening & Structural Reinforcement by HawT3D
Hidden design
#2 vesion 1 by DTHOANG
#1 Modify-062425 by CUONGNGUYENVANDUY
Hidden design

Discussion

willsaltz

Designer

Sun, 20 Jul 2025 14:24:11 +0000
Hi Jonathan,
Would I be able to design these grill inserts on Fusion 360?
Sun, 13 Jul 2025 19:05:31 +0000
Hi Mate, The grill can go in from the back or front. And yes it is acceptable that the bull bar must be removed entirely to access the clips
Sun, 13 Jul 2025 19:03:55 +0000
Hello, Is the plastic grille designed to be inserted from the front, i.e. towards the vehicle? Does the plastic grille need to be removable while the bull bar is installed on the vehicle, or is it acceptable that the bull bar must be removed entirely to access clips, screws on the interior?

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