Thomas J. Schnell – Industrial Design Portfolio

MY WORK

Five Gallon Gas Cans

2019 – 2020

THE PRODUCTS

Scepter is a global leader in the manufacture of durable, blow molded fuel containers for consumer, military, and marine markets. In 2019-2020, they partnered with DiMonte Group to redesign and recommend changes for two of their iconic gas cans.

MY CONTRIBUTIONS

  • Optimized overall dimensions for efficient pallet packing and point of sale
  • Conducted rigorous ergonomic testing to refine handle and spout placement
  • Produced dozens of styling sketches that balanced aesthetics with functionality
  • Leveraged my knowledge of blow molding to inform design decisions
  • Utilized advanced surface modeling in SolidWorks to achieve smooth, organic geometry

RV STYLE GAS CAN

STANDARD 5 GALLON GAS CAN

Optimizing Dimensions for Shipping Efficiency

Scepter ships millions of gas cans annually across North America, making shipping optimization a critical cost driver and design factor. I developed a decision matrix that evaluated overall product dimensions, gasoline volume, handle size, and shipping efficiency for standard US trailers. This process helped us determine the ideal dimensions for Scepter’s popular 5-gallon can, maximizing space while maintaining functionality.

Designing for Point of Purchase

Additionally, I considered retail display constraints, using insights into standard shelf dimensions at Walmart to influence product height, width, and depth. Low-fidelity renderings were created to visualize how the product would appear on shelves, ensuring an attractive in-store presence.

Ergonomic Testing

To ensure optimal usability, we developed a modular mockup that allowed for quick adjustments to handle height and size. I conducted extensive ergonomic testing with users of various sizes and age groups, refining the design to enhance comfort and accessibility. This hands-on approach enabled us to identify additional opportunities for ergonomic improvements.

Industrial Design Styling

My styling sketches were developed to stay true to Scepter’s brand identity while introducing a sleeker, more robust appearance. Each sketch carefully integrated findings from ergonomic testing, dimension optimization, and manufacturability considerations, ensuring a cohesive design that balanced aesthetics and practicality.

Advanced 3D Modeling in SolidWorks

Leveraging my expertise in blow molding and SolidWorks, I created a stable 3D model that captured the essence of the industrial design vision. Using advanced surface modeling techniques, I sculpted smooth, organic transitions between faces, ensuring the final product met both aesthetic and functional requirements.