When critical legacy parts fail—and replacements are no longer available—reverse engineering with 3D scanning is often the fastest, most precise, and most cost-effective route to getting things back in motion.
One of the UK’s largest bus operators, Go-Ahead London, faced a serious problem: the specific replacement parts for their Holset HE200VG turbos were no longer manufactured. Without these parts, the only alternative was to replace entire turbo units—an expensive and unsustainable option for a large fleet.
3D Scanning of Existing Components
Our high-precision 3D scanning services captured the exact geometry of the obsolete turbo components, creating a digital blueprint for production.
Material Specification Identification
We analysed and matched the original material specifications to ensure performance and durability equal to—or better than—the originals.
CAD Modelling & Engineering Drawings
From the scan data, our engineers produced accurate CAD models and engineering drawings ready for outsourcing for manufacture.
Prototype Development
We helped our client develop a working prototype for testing in their fleet before committing to the low volume production of further replacement parts.
Significant Cost Savings — Replacing only the worn turbo parts instead of entire units.
Sustainability — Extending the lifespan of equipment and avoiding unnecessary waste.
Proven Performance — Reverse-engineered components performed flawlessly in operational testing.
| Benefit | Why It Matters |
|---|---|
| Speed | Design-ready CAD files in days, not weeks. |
| Precision | High accuracy for complex shapes and geometries. |
| Cost Efficiency | Focused replacement avoids expensive full-unit swaps. |
| Flexibility | CAD models make future reproductions simple. |
| Sustainability | Repair over replacement reduces environmental impact. |
Once we create your digital CAD model, it’s yours forever—allowing rapid future manufacturing of the same part via 3D printing, vacuum casting, or CNC machining.
Lost drawings? Legacy parts? Complex geometries?
Let us help you recreate them with precision. Get in touch today to discuss your reverse engineering project.