Reverse Engineering Services for Obsolete, Worn and Unavailable Parts
When replacement parts are no longer available, machine manufacturers have ceased trading, or critical production equipment is becoming difficult to maintain, our reverse engineering services help you recreate the components you need.
Using advanced 3D scanning and CAD modelling technologies, we capture accurate digital data from existing parts and assemblies, producing detailed CAD models and manufacturing drawings suitable for remanufacture.
Whether you need a single worn component reproduced, a complete assembly reverse engineered, or legacy engineering data recreated from physical parts, we provide practical solutions that help reduce downtime, extend equipment life and maintain production capability.
Common Reverse Engineering Applications
- Obsolete and unavailable machine parts
- Legacy manufacturing equipment
- Production line spares
- Food processing machinery
- Pharmaceutical manufacturing equipment
- Castings with no drawings
- Components from discontinued products
- Worn or damaged parts requiring remanufacture
Our Reverse Engineering Process
Whether you need to recreate an obsolete machine component, replace a worn production part, or recover missing engineering data, our structured reverse engineering process ensures accurate and reliable results.
Step One: Capture the Existing Part
We begin by inspecting and measuring the component or assembly. Depending on the application, we use high-accuracy 3D scanning, traditional measurement techniques, or a combination of both to capture the geometry and critical features of the part.
This approach allows us to recreate components where no CAD data, drawings or manufacturer information exists.
Step Two: Establish the Original Design Intent
Reverse engineering is more than simply copying the geometry of an existing component.
Parts may be worn, damaged, distorted or modified during their working life. We assess functional features, interfaces, symmetry, fits and likely manufacturing intent to determine what should be recreated and what should be corrected.
Where appropriate, we can also incorporate improvements to materials, geometry or manufacture while maintaining compatibility with the existing equipment.
Step Three: Create CAD Models & Manufacturing Drawings
Using the captured data and established design intent, we create accurate 3D CAD models and detailed engineering drawings.
These files can be used for:
• Remanufacturing obsolete parts
• Producing replacement machine components
• Modifying or improving existing designs
• Creating digital records of legacy equipment
• Supporting quality control and inspection processes
Step Four: Delivery & Support
We deliver the CAD data, engineering drawings and supporting manufacturing information required to reproduce the component with confidence.
Where required, we can also support material selection, manufacturing route selection, supplier liaison and dimensional verification to help ensure the replacement part performs as intended.
The result is a practical engineering solution that helps reduce downtime, extend equipment life and maintain production capability.
From Reverse Engineering to Manufacture
Reverse engineering doesn’t have to stop at the CAD model. Where required, Plan D can support the complete route from an existing component through to a replacement part.
Depending on the application, this can include material selection, manufacturing process selection, supplier liaison, prototype production, 3D printing, machining and dimensional verification.
This allows customers to use Plan D either for a specific stage of the reverse engineering process or as an engineering partner to help take an obsolete or unavailable component all the way from physical part to manufactured replacement.
Have an obsolete, worn or unavailable component? Send us some photographs and a brief description of the application and we’ll advise on the best route to recreate it.
“Having engaged with Plan D on a project, it was clear from the get go that their vast amount of knowledge and experience were a pivotal tool wielded to ensure that the project was delivered on time and in-line with the project parameters. Clearly a talentented and highly knowledgeable team who I would highly recommend working with to leverage his expertise. Very personable and cut straight to finding the right solution. Look forward to continuing the working relationship going forward.”
Dan Johnson
Business Development Manager – KS Composites