Reverse engineering
Parts after
production ends.
Reproducing discontinued components from surviving parts, broken references and the equipment they fit.
The machines still worked. The broken grilles were the reason they were sitting idle.
Our client’s air-mover safety grilles broke regularly. Once the original manufacturer discontinued the replacement, finding another grille became the obstacle to using the equipment.
Josh worked from a surviving original, reverse engineered its geometry and printed replacements. The photograph shows three versions in PETG, PETG-CF and polycarbonate.
The aim is to return the client’s fleet to service. The pieces are prepared for delivery; installation, suitability checks and the operating result are still ahead.
The value in
a small part.
A discontinued component can leave an otherwise useful machine with a much more expensive replacement bill. Reproducing the component makes it possible to compare the cost of a custom part with replacing the equipment around it.
We work from existing parts wherever possible. The original shape, mounting points, clearances and operating conditions inform the model and the material. 3D scanning can help capture geometry; measurement and CAD help reconstruct the details that matter to the fit.
A surviving original is useful, though a broken part or the mating assembly can also provide a reference. The design and printing work are scoped around the particular job.
