Outlander

Overview

Outlander is a battery-powered external water filter heater designed to prevent backpacking water filters from freezing in cold environments. The project was developed as part of a team-based Introduction to Engineering Design course and focused on creating a practical, low-power, and portable solution for real-world outdoor use.

Problem & Constraints

Backpacking water filters can fail when exposed to freezing temperatures, making them unreliable in winter conditions. Existing solutions are often bulky, passive, or require keeping the filter inside clothing during use. The design needed to be lightweight, battery-powered with multi-hour runtime, safe for use around drinking water, and developed under academic time and budget constraints.

My Role & Design

I worked primarily on the power and control subsystem, including battery selection and sizing, power delivery to the heating element, basic control logic, and testing. The system uses a resistive heating element powered by a lithium-ion battery and controlled through a simple regulation and switching circuit. Insulation was selected to maximize thermal efficiency while minimizing power consumption, balancing heat output, runtime, and user safety.

PCB Design

I designed the power and control PCB using KiCad, focusing on reliable power delivery to the resistive heating element. This included battery selection and sizing, component selection, schematic capture, and PCB layout with attention to current handling, safety, and simplicity.

PCB Housing

I designed the PCB enclosure in Fusion 360 to securely house the electronics while keeping the system compact and lightweight. The enclosure was designed to protect the board during outdoor use and allow for easy integration with the heating element and insulation.

Battery Housing

I designed a separate battery housing in Fusion 360 to safely contain the lithium-ion battery pack. The design prioritized protection, accessibility, and strain relief for wiring, while maintaining a form factor suitable for portable, cold-weather use.

Testing & Results

I designed and assembled the power and control circuitry and integrated the heating element and insulation into a compact form factor. Testing showed the system successfully maintained the filter temperature above freezing, achieved multiple hours of continuous operation on a single charge, and demonstrated reliable, repeatable heating performance in cold conditions.

Heating Element

I tested the heating element to evaluate heat output, power draw, and temperature stability, confirming reliable performance in cold environments.

Temperature Graph

Temperature data shows the heated system maintaining the filter between roughly 40°F and 50°F, while an unheated filter would steadily fall below freezing under the same conditions.

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