Design and Development of a Plastic Fuel Tank

This thesis explores the design and development of a plastic diesel fuel tank for counterbalanced forklifts. The current welded steel tank increases production costs and limits design flexibility. Replacing it with a plastic alternative aimed to lower material costs, improve manufacturability, and increase compatibility without compromising safety or functionality. The project followed a structured product development process using Ashby’s method and fuzzy analysis, including material and manufacturing selection. A rotationally molded LMDPE tank was designed, evaluated through FEM and meshless simulations, and compared to industry standards. Results show the plastic tank meets structure requirements under load and braking scenarios. Although integration costs raise the total system price, the long-term benefits in durability, manufacturing efficiency, and flexibility support its viability.