Turbo Reverse Engineer

 

Design | Reverse Engineering
Industry: Transport

The Challenge

Go-Ahead London, one of the UK’s largest bus operators, faced a major challenge in maintaining their fleet. The critical repair parts for Holset HE200VG turbos were no longer available, leaving them with the costly option of replacing entire turbo units. With a large fleet to manage, this would have created significant financial strain and increased operational costs. The company needed a cost-effective and sustainable alternative to extend the lifespan of their existing turbo systems.

 

The Solution

We partnered with Go-Ahead London to reverse-engineer the unavailable turbo components, ensuring high-quality replacements that matched original performance standards. Using advanced 3D scanning, we generated accurate CAD models of the worn parts, identified material specifications, and created detailed engineering drawings to support sourcing and manufacturing. This allowed us to develop a working prototype for fleet testing, enabling the client to repair existing turbos rather than replace them entirely.

The Results

  • Significant reduction in operational and replacement costs.

  • A sustainable solution that extended the lifespan of their bus fleet.

  • Proven effectiveness, with re-engineered parts successfully tested in service.

  • Demonstrated AME’s capability to solve complex engineering challenges with practical, cost-saving results.