Key Design Features

• Optimized One-Way Valve Mechanism
Designed to allow controlled evacuation of crankcase gases while preventing intake backflow, supporting smoother engine operation.

• Compact Housing Design
Space-efficient geometry for integration into tight engine bays — compatible with both diesel and petrol configurations.

• Heat-Resistant Thermoplastic Body
Constructed using high-temp polymers capable of withstanding engine block heat, oil vapor exposure, and cyclic pressure loads.

• Viton® or Fluor elastomer Sealing
Ensures long-term chemical resistance and airtight operation even under fluctuating pressure conditions.

• Flow-Rate Tuned Internal Geometry
CFD-optimized channel design for consistent and controlled gas evacuation without pressure spikes.

Engineering & Validation

Our team ran flow simulations (CFD) to analyse pressure drop and velocity at various engine RPM conditions, followed by mechanical stress analysis to ensure structural integrity during long-duration thermal cycling. Rapid prototyping was conducted using high-temp SLA materials for initial assembly validation.
Material trials included nylon composites and PEEK, with production recommendations tailored to the client’s injection moulding capabilities.

Outcome

The final PCV valve design was delivered as a tool-ready CAD package with validated test results, and is now under consideration for deployment in next-gen engine platforms across Europe and Asia. This project highlights our ability to engineer functional, emission-critical components that balance performance, durability, and cost-efficiency in highly constrained environments.