Project Overview

While on site in Port Kennedy, WA for another project, Rescan 3D was asked to reverse engineer a broken gearbox cover from a CNC lathe. The client, a local machine shop, planned to manufacture their own replacement but needed an accurate 3D model of the original component for CAM programming.

Services: 3D Scanning · Reverse Engineering
Component Size: Approx. 230 × 100 × 100 mm
On-Site Scanning: Approx. 15 minutes
Reverse Engineering: Approx. 1 hour
Deliverable: STEP CAD model
Application: Replacement component manufacture

The Challenge

The existing cover was broken and deformed, so simply copying its scanned shape would not produce a usable replacement. The original geometry needed to be reconstructed while preserving the mounting points and clearances required for the new part to fit the existing machine.

3D Scanning & Reverse Engineering

We scanned both the damaged cover and the area where it mounted to the lathe using an EinScan Rigil 3D scanner. The scan data was then used to reconstruct the damaged component as a clean CAD model, correcting the deformation while retaining the dimensions and features needed for installation.

The finished CAD model was compared against the scan of the original component to check its overall shape and dimensions. We also compared the model with the scan of the lathe itself to confirm that the replacement would fit correctly within the available space.

The Outcome

A manufacturing-ready STEP model was supplied to the client for production of a replacement aluminium cover. The client planned to first 3D print the model to verify fit before machining the final component.

Because the scanning was completed during a site visit for another project, all of the additional data needed to reverse engineer the replacement part was captured in approximately 15 minutes on site.