Carbon Fiber Hinge Redesign

I have a metal hinge that currently works well but I need one that is longer and slightly more narrow to fit a tight space. I have remodeled the components but the nature of the hinge requires precise dimensions for it to work properly. It's a concealed hinge. I will make compression molds and the part will be made from carbon fiber. In addition. I have a locking/latching mechanism that I have about 80 percent there but need some help to get it over the finish line. This would involve an actuator and a latch that connects with a pin and applies a small amount of pressure to compress a gasket. I have CAD for both that can be provided in step or IGES format.

Because the hinge will be part of a mass-produced consumer device, it has to handle high load-bearing situations, resist corrosion in everyday environments, and survive thousands of open-close cycles without loosening or creaking. The new design should respect the original kinematics while taking full advantage of carbon fiber’s anisotropic strength. If metal inserts, bushings, or alternative pin materials are needed to reach the required durability, feel free to propose them.

For clarity, here is what I’d like back:

• Native 3D CAD model (STEP + source format)
• 2D manufacturing drawings with tolerances and recommended fiber lay-up schedule
• Basic FEA summary showing that the new geometry meets the load, corrosion-resistance, and longevity targets
• A short note on tooling considerations for compression molding, including draft angles and parting lines

I can provide any additional measurements, photos, or functional data you need. Let me know your preferred CAD platform and your estimated timeline so we can get started right away.