Casing Reverse Engineer

 

Design | Reverse Engineering | Rapid Prototyping
Industry: Transport

The Challenge

A client operating a large bus fleet 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

We reverse engineered the broken casings by first 3D scanning the damaged parts to capture their dimensions with precision. Using CAD design, we created accurate models that replicated the original geometry while making minor adjustments to ensure a perfect fit within 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 reverse engineering and 3D printing for practical, real-world transport solutions.