Reverse Engineering & Part Reproduction.
Reverse engineering for part reproduction, competitive analysis, and failure-driven redesign — producing dimensioned drawings and 3D files in native and neutral formats.
Applications cover obsolete part reproduction, analysis of existing solutions to inform original design, and redesign where a structural weakness is identified.
Physical production available through our machining network; clients outside the EU are supplied with manufacturing-ready files for local production.
TRANSMISSION HUB (Children's Electric Ride-On Vehicle)
The original transmission hub on this children's electric ride-on vehicle was a single-piece moulding — gear teeth and hub integrated. When the teeth stripped, the entire drivetrain was unserviceable and the vehicle effectively written off.
The worn gear section was turned down on a lathe to just above the existing internal webbing, preserving the structural core of the original hub. A replacement gear was designed as a cup profile, with internal geometry matched to the existing webbing — using it both as a positive torque transmission interface and as a mechanical lock. Three bolt holes through the cup gear were drilled into the turned-down hub centre, securing the assembly.
The result is a retrofitted hub with a field-replaceable gear. When teeth strip, the gear is unbolted and replaced — no specialist tooling, no press fitting, no replacement of the entire assembly.
Client
Konstantinos Damianakis
Year
2023
Door Handle Replacement — Citroën Saxo (1997)
The door handle lever on this 1997 Citroën Saxo had failed at a predictable stress concentration in the geometry — during COVID lockdown, when parts availability was reduced and non-OEM pricing had risen accordingly. Replacement parts are available from non-OEM suppliers — but only as a complete assembly including the handle shell, springs, pins, and plastic locks. With the rest of the assembly intact, buying the complete unit to replace a single broken lever was neither economical nor practical.
The lever was reverse engineered from the physical part, modelled to original dimensions, and redesigned with reinforced geometry at the failure point. The replacement was 3D printed as the final production part — a viable end-use solution for a low-load application where additive manufacturing matches the mechanical requirements and eliminates both tooling cost and unnecessary assembly replacement.
Client
Internal Project
Year
2020