Circular Catch Basin

Wong, Bryce. 2022. Circular Catch Basin. U.S. Patent 11,512,803, filed September 9, 2020, and issued November 29, 2022.

Designed and manufactured in California.

Circular Catch Basin – An overview

I engineered the Circular Catch Basin to address industry demand for a compact, high-performance stormwater capture solution, integrating an innovative outlet knockout system that enables users to convert the standard 3" outlet to a larger opening for increased flow capacity. This feature provides installers with configurable flow performance without requiring separate SKUs or field-fabricated modifications.

The product was fully developed in SolidWorks, where I performed detailed geometric modeling, drafted manufacturing-ready drawings, and executed design-for-manufacture optimizations. Using finite element analysis (FEA), I evaluated structural deflection, stress distribution, and load response under typical installation and soil conditions. Through iterative analysis, I refined the rib architecture and material distribution to reduce overall weight by approximately 30% while maintaining required safety factors.

I leveraged 3D printing to rapidly validate form, fit, assembly interfaces, and functional behavior of the knockout system, allowing early detection of potential issues and accelerating the design cycle. I also led cross-functional technical reviews with tooling, manufacturing, sourcing, and marketing teams to ensure readiness for mass production and alignment across program milestones.

To ensure a robust manufacturing process, I conducted comprehensive Moldflow simulations—evaluating fill, pack, and warp behavior to identify potential short shots, pressure imbalances, weld lines, and deformation risks. These analyses guided gating strategies, wall thickness adjustments, and rib optimization, ensuring consistent part quality and minimizing downstream production issues.

The resulting product delivers a lightweight yet structurally robust catch basin that offers configurable hydraulic performance—attributes that have made it a customer favorite and a strong performer in the field.