Thermal Armor: Emergency Heat Shield Redesign for the XR-7 Turbo Downpipe

Context

RevTech Automotive has a serious problem. Their XR-7 performance sedan launched six months ago with a turbocharged 2.5L engine, and warranty claims are spiking. The flexible brake line running 40mm from the downpipe is degrading prematurely—rubber compounds are hardening, and three customers have reported soft pedal feel traced to heat-damaged lines. The current stamped aluminum heat shield was a cost-down decision that's now costing more in warranty than it saved.

You've been pulled into an emergency redesign. The catch: the 2026 model year tooling freeze is in 8 weeks, and any solution must use existing mounting points. RevTech's thermal team measured 680°C surface temps on the downpipe at sustained highway speeds, and the brake line sheathing is rated to 150°C max continuous exposure.

Your Goal

Design a replacement heat shield system that reduces brake line exposure temperature to below 120°C (with margin) while meeting packaging, cost, and manufacturing constraints. You must evaluate at least three distinct concepts and justify your final selection with quantified trade-offs.