How We Developed a Custom Fuel Filter That Didn't Exist

OE development isn't like ordering from a catalog. You start with a concept, a set of requirements, and a blank page. When an internationally recognized off-road vehicle brand needed a miniature fuel filter that nobody manufactured, they came to us. Here's how we took it from zero to production.

The Challenge

No factory on the market produced fuel filters this small. We needed to find a manufacturer with the right domain expertise, collaborate on a new design, validate performance against stringent OE requirements, and bring it to volume production — all while keeping the client fully informed at every stage.

Step 1: Supplier Audit & Selection

We identified multiple candidate factories specializing in fuel filter production and ran full audits. Each supplier received a detailed Dolphin Report covering facility capabilities, equipment, quality systems (QCLDM scoring), and production capacity. The client got a transparent view of each factory's real capabilities — no guesswork.

Step 2: Co-Design & Prototyping

Working with the selected factory's engineers, we developed the part drawings from the client's prototype requirements. Their fuel filter manufacturing experience, combined with our engineering oversight, produced a design optimized for both performance and producibility.

Step 3: Testing & Problem-Solving

Third-party performance testing revealed a critical failure: burst strength was below specification. Our engineers identified the root cause — adhesive formula and dosage — and spent six weeks running experiments to solve it. That kind of hands-on technical problem-solving is what separates managed sourcing from simple order placement.

Step 4: Production & Ongoing Quality

During trial production, our QA team spent a full month embedded at the factory. For bulk production, we maintained continuous oversight through video conferences, on-site verification, and real-time reporting. The client always knew exactly what was happening on the production floor.