The problem presentedto the team by SteelTech Inc. was to recommend a number of design modifications to theG-Series furnaces to improve the serviceability of the furnace,as well asto make components modular. Due to the time constraints, the team focused on improving the furnace insulation andmaking the smoke bypass system modular.Afterconcept generation, selection processes, and collaboration with SteelTech, the team decided on the insulation and by-pass concept’s to further develop. Polyiscocyanurate(ISO) Rigid Foamand the direct by-passwas our final concepts thatwasfurther developedin the report.The final insulation design consists of ISO rigid foam sheets installed inside the exterior panels of the boiler. This design provides a greater thermal resistance rating of R-21.5, whichwas over theproject need of R-19. Additionally, repairs and their servicing time, had been made shorter due to the insulated panel design, becauseremoving the panels allowstheuserfull access to the internal boiler components. Another advantage of this design,is that it allows incoming air to be preheated before entering the combustion chamber due to the increased air gap space between the insulation and water jacket, which increases the efficiency of boiler. The final design of the bypass systemis a simplifiedadaptation of SteelTech’s current designwhich allowed the new boiler design to becomemodular. The shaft is inserted from the side of the boiler and engages inside of a hub welded onto the bypass valve. As well as being modular, this design can be easily fabricated with common manufacturing techniques that can be done in-house at SteelTech.