Your equipment is becoming outdated, and the parts are impossible to easily replace.
The original manufacturer is no longer producing replacements parts or has gone out of business. Purchasing new equipment is a significant expense, and you are hoping that reverse engineering will be the solution to your problem.
3D scanners make it possible to replicate and reproduce legacy parts, but this isn’t always the best fit for your unique situation. There are several factors to consider before you decide if this is the right way to go.
Let us explain some of the limitations of reverse engineering legacy parts to help you make an informed decision on if it’s right for you.
How Detailed Are Reverse Engineered Parts?
The accuracy of 3D scanners has improved by leaps and bounds since the technology was first invented. Advancements in technology and feedback from customers have helped companies that produce these scanners refine their products over the years.
Even the best scanner has its limits, and you will need to take that into consideration before moving ahead with the process of having it reverse engineered.
Limitations of 3D Scanners
Today’s 3D scanners can produce extremely accurate scans if the part or product you want reverse engineered meets some particular criteria. Ask yourself the following questions before determining if it will be possible to replicate your part.
3 Questions to Ask
1. What condition is it in? A gear with missing teeth, cracks, or surface damage would be difficult to produce an accurate scan of.
2. Is the part too small? Tiny parts are troublesome for scanners to pick up all the details on.
3. How intricate is the design? If there are lots of tiny, intricate details, the scanners could miss them.
Recommended Reading: Limitations of Reverse Engineering
In some cases, it’s possible to fix inaccuracies created during the scan.
Consult a professional if you are unsure your component can be accurately scaled without missing any details.
How a Legacy Part is Reverse Engineered
Step 1 - Get a Scan
A 3D scanner is used to obtain exterior information about the component being scanned. It produces a dense, triangle mesh that will serve as a visual sketch. This sketch can be easily manipulated with CAD to make adjustments as necessary.
Step 2 - Refine Your Model Using CAD
The mesh model that was created by the scanner will be turned into a polygonal model so it can be adjusted. The mesh model will be cleaned up, smoothed, and sculpted to ensure it captures the shape of the original component accurately.
Step 3 - The Component is Reproduced
Once all the necessary changes have been made to the CAD model, your part is ready to be manufactured. There are several ways to manufacture a part. Depending on how big the object you want to reproduce is, a 3D printer could be used for this step. In some cases, a 3D printed model can give you the opportunity to see how it stacks up against the original before mass-producing it. This can help prevent wasting wads of cash making a ton of parts that won’t work.
San Francisco Municipal Transportation Agency (SFMTA)
The SFTMA has originally been under contract with AnsaldoBreda. AnsaldoBreda manufactured 149 light rail vehicles for them before their company went out of business. This required SFTMA to find another solution for replacement parts. With the help of a new manufacturing company and 3D scanners, they have been able to reverse engineer 26 unique parts to repair the Muni trains.
Taylor Attachments
Taylor Attachments is a manufacturer of tractor headstock conversion brackets. They design and mass-produce headstock for the national agricultural and commercial industries. Their clients will bring them components that require restoration. With the use of their Artec Eva ED Scanner, they are able to get a complete scan of a headstock in approximately 20 minutes.
Up the Creek Workshop
Stuart Murdoch had been the owner of a Delage Type S since 1975. In 2014, the engine block was cracked around an exhaust valve. The damage was bad enough that it needed to be replaced, but Delage stopped making replacement parts long ago. Stuart needed to have the engine block reversed engineered so it could be replicated and replaced. He didn’t have access to the design drawings or other engines for reference, so he had to rely on 3D scanners to get an accurate model. They were able to get the job done after 9 months spent scanning, CAD modeling, and mold design.
Consult a Professional
If you are unsure about the scannability of your legacy parts, consulting a professional is your next step to take. Our top-notch staff of engineers can help you determine if reverse engineering would be ideal for your project, and guide you through the process every step of the way. Find out more about how we can help you revive your outdated equipment on our Services page.