Socket Connector Shroud Reinforcement Replacement

 

Design | Reverse Engineering | Rapid Prototyping
Industry: Transport

The Challenge

Go-Ahead London faced recurring issues with worn and broken casings in their modules. The damaged casings, which held plugs in place, caused operational difficulties, with some snapping entirely.
The only off-the-shelf option was to replace full modules, which would have been unnecessarily costly and wasteful. They needed a durable, cost-effective alternative that restored functionality without replacing whole units.

 

The Solution

Using CAD design, we created accurate models that replicated the original geometry while making minor adjustments to ensure a perfect fit alongside the existing modules. The worn tops of the old casings were carefully removed, allowing the new parts to be integrated flush with the module. Finally, the replacement casings were produced using Selective Laser Sintering (SLS), delivering strong, durable components capable of withstanding long-term use.

 

The Results

  • Delivered a cost-effective alternative to replacing full modules.

  • Produced durable, high-precision casings that restored
    functionality.

  • Reduced downtime by enabling fast repair and reinstallation.

  • Demonstrated the value of 3D printing for practical, real-world transport solutions.