Can’t Get the Spare Part? We Can Help.
When obsolete machine parts are no longer available from the original manufacturer, replacing the entire machine doesn’t have to be the only option. Plan D Design can reverse engineer worn, broken or existing components to recreate the engineering data needed to manufacture replacements — even when the original CAD models and drawings no longer exist.
Whether the original manufacturer no longer exists, a replacement is unavailable, only an expensive complete assembly is offered, or no original drawings exist at all, we can work from the existing component to help get your equipment running again.
Is This Your Situation?
Many manufacturers rely on machinery that has been in service for decades. The original manufacturer may no longer exist, replacement parts may have been discontinued, or OEM spares may only be available as expensive complete assemblies.
We help companies overcome problems such as:
- A critical machine has broken down and the replacement part is obsolete or unavailable.
- The OEM no longer supports the machine, they are obsolete machine parts.
- A relatively simple part is only available as part of an expensive complete assembly or spare-parts kit.
- No original CAD models or manufacturing drawings exist.
- The only available component is worn, damaged or broken.
- An existing part needs to be reverse engineered back to its original design intent.
- A replacement needs to be manufactured as a one-off or in small quantities.
- Production downtime means a replacement is needed quickly.
If you have the component — even if it is worn or damaged — there is a good chance we can help.
How We Help
Our reverse engineering service combines decades of engineering experience wOur reverse engineering service combines decades of practical engineering experience with modern 3D scanning, measurement and CAD technology.
We don’t simply create scan files. We are engineers who use 3D scanning as one of the tools required to recreate components that can actually be manufactured and put back into service.
Depending on the component and application, we can provide:
- Optical 3D scanning
- Precision measurement
- Reverse engineering
- CAD modelling
- Reconstruction of worn or damaged geometry
- Manufacturing drawings
- Dimensional inspection
- Design optimisation
- Manufacturing process and material advice
- Prototype and replacement component manufacture
Our experience across motorsport, automotive and complex engineering industries means we consider not only the shape of a component, but how it functions, how it was originally manufactured and how best to reproduce it.
Our Process
1. Assess the Component
We discuss the application, how the component functions, how it has failed or worn, and what the replacement needs to achieve. This allows us to determine the most appropriate reverse engineering, measurement and manufacturing strategy.
2. Capture Accurate Data
Using optical 3D scanning, precision measurement and, where appropriate, CT scanning or other inspection techniques, we capture the geometry of the existing component.
Not every feature needs to be treated in the same way. Critical interfaces, fits, mounting points and functional surfaces can be measured and assessed separately where greater control is required.
3. Reconstruct the Engineering Design
A scan represents the component as it exists today — including wear, damage and manufacturing variation.
Our engineers use the captured data together with an understanding of the component’s function and manufacturing method to create an intelligent CAD model. Where necessary, worn or damaged features can be reconstructed to recover the likely original design intent.
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4. Create Manufacturing Data
From the reconstructed CAD model we can produce production-ready manufacturing drawings containing the dimensions, tolerances, materials and other engineering information required to reproduce the component.
Where appropriate, the CAD data can also be supplied directly for CNC machining, additive manufacture, fabrication, tooling or other manufacturing processes.
5. Manufacture the Replacement
Where required, Plan D Design can take the project beyond reverse engineering and arrange or undertake manufacture of the replacement component.
Depending on the application, this may include machining, fabrication, 3D printing, moulding, casting or other appropriate processes — from a single replacement part through to repeat production.
Recent Projects
Food Manufacturing – Replacement Parts for Production Machinery
A major cereal manufacturer required replacement components for existing production machinery. The individual parts they needed were not available separately from the original equipment manufacturer and could only be purchased as part of expensive complete OEM spare-parts kits.
Plan D Design reverse engineered the individual components, producing accurate CAD models and manufacturing drawings so that replacement parts could be manufactured independently.
This gave the customer an alternative source for the components they actually needed, reducing the cost of maintaining the equipment and helping protect against future parts obsolescence.
Pharmaceutical Manufacturing – Unsupported 30+ Year-Old Machinery
A pharmaceutical manufacturer relied on a critical production machine that was more than 30 years old and no longer supported by the original manufacturer.
With replacement components becoming increasingly difficult to obtain, Plan D Design used 3D scanning, precision measurement and reverse engineering to recreate the obsolete machine parts and produce the engineering data required for manufacture.
By creating new CAD models and manufacturing drawings from the existing parts, the customer gained a route to producing replacement components independently — helping extend the working life of critical production equipment that might otherwise become increasingly difficult to maintain.
Reverse Engineering Across Industry
The same reverse engineering approach can be applied wherever replacement components, original engineering data or OEM support are no longer available.
- Food Manufacturing
- Pharmaceutical
- Automotive
- Motorsport
- Aerospace
- Defence
- Nuclear
- Industrial Manufacturing
- Classic Vehicle Restoration
Why Choose Plan D Design?
We’re engineers who 3D scan — not simply a 3D scanning company.
Capturing the geometry is only part of reverse engineering an obsolete component. The real engineering challenge is understanding what the component does, how it was manufactured, which features are critical, what has worn or changed during its life and what information a manufacturer needs to reproduce it successfully.
- Decades of mechanical engineering experience
- Former Formula One design engineers
- Advanced optical 3D scanning and precision measurement
- Engineering CAD modelling
- Production-ready manufacturing drawings
- Experience reconstructing worn and damaged components
- Manufacturing and material selection support
- UK-based engineering team
- Site visits available
- Fast response for production-critical requirements
FAQ
What if the original component is worn, damaged or broken?
This is common with obsolete machine parts. Depending on the condition of the component, we can reconstruct worn surfaces, missing features or damaged geometry using the remaining component, mating parts, symmetry, functional requirements and engineering judgement.
Where necessary, we can also measure surrounding components or assemblies to establish critical interfaces.
Can you reverse engineer an obsolete machine part if no original drawings exist?
Yes. In many cases, the physical component itself is all we need to begin the reverse engineering process. We can use 3D scanning, precision measurement and engineering assessment to recreate the component as a CAD model and produce new manufacturing drawings.
Where a component is worn or damaged, we don’t simply reproduce the worn geometry. Our engineers can assess its function, interfaces and likely original design intent to reconstruct the component appropriately.
Can you manufacture the replacement part as well?
Yes. Plan D Design can support the complete process from reverse engineering and CAD through to manufacture.
The appropriate manufacturing process depends on the component, material, quantity and application, and may include CNC machining, fabrication, 3D printing, moulding, casting or other manufacturing methods.
Can you reverse engineer just one replacement component?
Yes. Projects can range from a single urgently required replacement component to creating manufacturing data for parts that will subsequently be produced in batches.
For older machinery, creating the CAD model and manufacturing drawing also means the engineering data is then available if further replacements are required in the future.
What types of machine parts can be reverse engineered?
We can assess a wide variety of mechanical and industrial components, including brackets, housings, covers, guards, bearing carriers, machine elements, fabricated parts and more complex components and assemblies.
The best approach depends on the component’s function, material, tolerances and manufacturing method, so we normally begin by assessing the part and its application.
How quickly can you reverse engineer an obsolete machine part?
Timescales depend on the complexity of the component, the measurement required and whether manufacture is also needed.
We understand that obsolete components are often discovered because a machine has already failed, so production-critical requirements can be prioritised wherever practical. Contact us with photographs and some basic information about the component and we’ll advise on the likely approach and timescale.
If obsolete components, missing engineering drawings or unsupported machinery are affecting your production, we’d be pleased to discuss your project.
Whether you need a single replacement component or a complete reverse engineering programme, our experienced engineers are here to help.