When components fail repeatedly in high-use environments, the impact goes beyond simple replacement costs. For transport operators like Go-Ahead London, durability, reliability, and ease of maintenance are critical to keeping fleets operational and minimising downtime.
In this project, we worked closely with their team to resolve ongoing issues with door lock mechanisms and improve overall component performance using reverse engineering & vacuum casting.
Go-Ahead London identified recurring failures with the door lock mechanism and lever handle end on their vehicles. These issues were primarily caused by regular driver interaction and unintended misuse over time.
The original door lock cover moulding left the latch exposed, making it easily accessible. As a result, drivers would often use the latch directly, applying force in ways it wasn’t designed to withstand. This repeated stress led to:
Additionally, the lever handle end component was prone to wear and required a more robust and reliable solution.
To address these issues, we took a design-led approach focused on both prevention and durability.
We redesigned the door lock cover moulding to fully conceal the latch, eliminating direct access and preventing misuse. By removing the opportunity for incorrect handling, the new design protects the internal mechanism from unnecessary stress.
At the same time, we reverse-engineered the lever handle end to improve its strength and longevity while ensuring full compatibility with the existing assembly.
Both components were produced using vacuum casting, a process ideal for low-volume, production-quality parts. This allowed us to:
The updated components delivered immediate and measurable improvements across performance, durability, and cost-efficiency:
For this project, vacuum casting provided the perfect balance between speed, cost, and quality. It enabled rapid iteration and delivery of functional parts without the need for injection mould tooling, making it ideal for transport applications where downtime must be kept to a minimum.
By combining smart design improvements with the right manufacturing process, we helped Go-Ahead London reduce component failure, improve reliability, and extend the lifespan of critical vehicle parts.
If you're experiencing similar challenges with worn, failing, or poorly designed components, there’s often a more efficient solution than full replacement or traditional manufacturing routes.
Whether you're looking to redesign a failing component, reverse engineer an existing part, or produce low-volume end-use components, our team can help.
Get in touch to discuss your project.