It's a familiar situation: a production line stops because one custom component has failed, the original manufacturer has discontinued it or gone out of business, and no drawings exist. Buying a whole new machine costs a fortune. Reverse engineering the failed part is almost always faster and cheaper.
Step 1 — Scan whatever survives
Even a cracked, worn, or partly missing part carries most of the information we need. We scan it with the EinScan HX2 at up to 0.04 mm, capturing every intact surface as a dense point cloud. Damaged parts are normal for us — we've rebuilt gear teeth, snapped brackets, and corroded hardware.
Step 2 — Reconstruct the missing geometry
This is where engineering judgement matters. Our engineers reconstruct worn or missing features in CAD using the part's function, its mating surfaces, and symmetry. If you have the matching part from the other side of an assembly, or a photo of the original, we use those references to rebuild the exact geometry.
Step 3 — Manufacture the replacement
We remanufacture in the right process for the job: 3D printing for polymer parts and rapid replacements, CNC machining or casting for metal. Often this is the moment to upgrade the material — a stronger alloy, a more corrosion-resistant grade — so the replacement outlasts the original.
You also keep a permanent digital archive. The next time that part fails, remanufacturing takes days, not weeks, because the CAD already exists.
How long and how accurate
Rush turnaround starts from 72 hours; standard timelines vary by the size and complexity of the part. We guarantee dimensional accuracy to the agreed tolerance, and for critical parts we produce a 3D-printed validation prototype before committing to final manufacture.