When a supplier drops a spare part, a whole repair line dies. Not a product defect, not the end of a technical cycle - just a commercial decision made thousands of kilometres away from the field. Customers keep using their machines for 10, 15, 20 years. They need the part. We remake it.
Case in point - a chainsaw handle for the African market
A major manufacturer of professional thermal power tools had discontinued a rear handle. Problem: on the African market, chainsaws are not thrown away - they are repaired. Over and over. Without spare parts, thousands of perfectly functional machines are condemned for a single broken piece of plastic.
Our mission: full reverse engineering and production of a 5,000-unit run in ABS.
The process: high-precision 3D scan of the original (micron-level point cloud), CAD reconstruction into a perfect geometry (not a copy of the worn part's defects), delivery of 2D drawings and STEP file, steel mould fabrication, then 5,000-unit injection production in ABS.
Why scanning alone is not enough
Many believe a 3D scan is enough to remake a part. It is not.
The scan captures the object as it is: scratches, warping, wear. A 15-year-old part that has endured thousands of hours of vibration no longer has its original geometry. Inject that raw scan and you mass-produce a pre-deformed part.
The solution: we rebuild the theoretical geometry. Our engineers convert the point cloud into perfect mathematical surfaces, with the functional dimensioning reconstructed from the part's actual use.
⚠️ Warning: some design studios deliver the raw STEP from the scan. It works for a prototype - not for a series. Always demand parametric CAD reconstruction.
Plastic, metal, cast aluminium - we are not limited to a single material
Most spare parts are not pure plastic. A single machine housing can combine injected ABS handle, cast aluminium base, machined steel shaft, overmoulded TPE seal. We handle the full chain: plastic injection (ABS, fibre-filled PA66, PC, TPE) for any series size, cast aluminium through our qualified European partners, and precision machining on reverse-engineered drawings.
We do not outsource the engineering. The drawings and the orchestration stay in-house. That is what guarantees dimensional consistency across materials.
When reverse engineering pays off
Our tip: RE makes sense as soon as the OEM has disappeared or discontinued the line. If the OEM is still selling the part, check their catalogue first - sometimes ordering direct is simpler. But once the line is dead, remaking the part is your only option. And if you have a captive market (aftersales, repair business, export to high-repair regions), the tooling investment amortises quickly over the series.
What we deliver
2D drawings and parametric STEP file, injection mould in P20 or 1.2311 steel, full production run with first-article quality control. Ownership of the drawings: they belong to you. We never resell drawings to a third party.
Got a discontinued part on your hands?
Send us the physical part (or a scan if you already have one). We review feasibility free of charge and come back with a full quote within 5 working days.
FAQ
How long does a full reverse engineering project take?
Scan plus CAD: around 2 weeks. Mould: 6 to 8 weeks. First production parts: 8 to 10 weeks after go-ahead.
Can the part be improved during the reverse engineering?
Yes, and it is often recommended: reinforcing ribs, correcting the original sink marks, switching to a better-aging material if needed.
Do you only do plastic?
No. We orchestrate plastic, cast aluminium and machining through our European partners. The drawings and the engineering stay in-house.
Who owns the 3D files once they are delivered?
You do. Contractually, we never resell your drawings to another customer.
What is the minimum sensible production run?
From 1,000 parts for a simple plastic, 3,000 for a technical part. Below that, we favour 3D printing or machining.
