Design of Speed Mud Edition Muffler : RJ Weld & Custom (RJWC)

Abstract: The report was a result of the master thesis work for Industrial Design Engineering at Luleå University ofTechnology during spring 2021. The whole project was directed towards RJ Weld & Custom (RJWC) locatedin Boden on one of their best-selling aftermarket mufflers for the ATV, the Mud Edition.The purpose of the project was to develop the outside and inside of the Mud Edition muffler regarding design,material, and sound using a Human-Centered design approach. The Mud Edition muffler was assembled inBoden but separate parts were manufactured in China. RJWC had the opportunity to manufacture parts bythemselves as well, foremost in aluminum, steel, and carbon fiber. The goal of the project was to solve sometechnical aspects of the Mud Edition muffler and to come up with a new concept.The project has been carried out using the design thinking process throughout four design sprints. During thefirst design sprint, the design team investigated the problems and needs that exist today with the Mud Editionmuffler by conducting interviews and sending out surveys. During the second design sprint, the project teamidentified the current situation at RJWC with the help of literature studies and benchmarking. It was identifiedthat the sound desire of a muffler varies, more robust or more fun appearance is also desired and the ease ofassembling a muffler. The third and fourth design sprints focused on the design details and presentation of thefinal concept.Creative workshops and feedback sessions with RJWC were conducted for the identified issues and improvement of the solutions throughout the whole process. We implemented, tested, and evaluated. The result wasa reduced version of the Mud Edition muffler to facilitate shipping and assembly, new modern design thatreplaces welding and screws with Toggle Locks, V clamp, and Middle clamps.The design team hopes that the project can show the potentials of designing a muffler that looks different from the other typical mufflers in the market today. We hope that this project can inspire future workto think outside the box and embrace change to favor the user’s needs. The muffler is an important partand is visible on the ATV, we encourage the market to use details that make it more exciting to look at.