Reverse Engineering Service
When original tooling is damaged, worn, or unavailable, our reverse engineering service recreates parts from physical samples. Using 3D scanning, CAD reconstruction, and rapid mould fabrication, we deliver production-ready replacement moulds in 5-6 weeks—rescuing discontinued products and obsolete spare parts.
3D Scanning & Digitisation
Our ATOS GOM structured-light scanner captures part geometry with accuracy to ±0.01mm. The resulting point cloud is processed into a watertight CAD model suitable for mould design. For parts with complex internal geometry, we supplement external scanning with CT (computed tomography) scanning.
CAD Reconstruction
Raw scan data is converted to parametric CAD (SolidWorks/NX) with intentional design modifications: draft angles optimised for moulding, undercuts eliminated where possible, wall thickness uniformised for consistent quality. The client approves the final CAD before mould fabrication begins.
Mould Fabrication
New moulds are CNC-machined in P20 or H13 tool steel depending on production volume and material requirements. Where the original part had moulding defects (sink marks, weld lines), we improve the mould design to eliminate them.
Quality Validation
First articles are dimensionally compared to the original part via 3D scan overlay. GD&T analysis ensures functional dimensions meet specification. Material testing (MFI, tensile, impact) validates that the replacement matches original performance.
Applications
Automotive spare parts (discontinued interior trim, clips, covers), appliance repair (handles, knobs, bezels), industrial machinery (guards, covers, bushings), consumer electronics (housings, battery covers), and medical device replacement components.
Frequently Asked Questions
How close is the reproduction to the original?
Dimensional accuracy: ±0.1mm for critical features, ±0.2mm overall. Material matching within the same polymer family. Colour matching via spectrophotometer to ΔE <1.0.
What if the original material is unknown?
We perform FTIR (Fourier Transform Infrared) spectroscopy and DSC (Differential Scanning Calorimetry) to identify the polymer type, filler content, and additive package. This ensures material-equivalent replacement.
Technical Specifications
Scanning accuracy: ±0.01mm | CAD software: SolidWorks, NX | Mould steel: P20, H13 | Mould delivery: 5-6 weeks | Material ID: FTIR + DSC | Dimensional validation: 3D scan comparison