Workshop bench with tools and reverse-engineered automotive parts

Engineering Success Stories

From bespoke one-offs to reverse-engineering obsolete components, we help clients solve critical supply and design challenges.

Automotive-style electrical connectors on a harness

Project details are anonymised to protect client confidentiality.

Case Study 1

Reproducing obsolete electrical connectors

Problem: A manufacturing client faced intermittent faults on a 1990s PLC system. The root cause was a cracked PEEK connector housing that held critical pins in place. The OEM no longer supported the part and used inventory was unreliable.

Approach

•Reconstructed geometry from fractured fragments
•Rebuilt worn latch features and keying details in CAD
•Validated pin alignment and mating fit before production

Manufacturing & materials

•Process: resin 3D printing for short-run production
•Material: rigid glass-filled resin for stiffness and thermal resistance

Result

•Replacement connectors delivered as a consistent batch
•System restored and back online in 4 days

Industry:: manufacturing and automation
Part type:: connector housing
Method:: reverse engineering and resin 3D printing
Turnaround:: 4 days

Need an obsolete connector reproduced? Contact us with a sample.

Fiat 1100/103 water pump seal 882723 - the reproduction we supply

The water-pump seal we supply for the Fiat 1100/103 - a reproduction from a specialist supplier.

Case Study 2

Sourcing a discontinued water-pump seal for the Fiat 1100

Problem: A client restoring a Fiat 1100/103 needed a reliable water-pump seal, but the original Fiat part has been out of production for decades, and the few surviving originals are as perished as the ones they would replace - without a sound seal the pump weeps and the car cannot be trusted on the road.

Approach

•Sourced a new reproduction of the complete seal assembly from a specialist supplier
•Handled the purchase and the delivery to the client

Manufacturing & materials

•Supplied as a ready-made reproduction from a specialist supplier - not manufactured by Replique labs
•Complete assembly: brass body and rings, carbon slip ring, rubber bellows and spring

Result

•Delivered to the client new and complete, ready to fit
•The same seal can now be ordered online from its part page

Industry:: automotive restoration
Part type:: water-pump seal assembly
Method:: sourcing and resale

Part page: Fiat 1100 water pump seal 882723

Can't find an obsolete part? Contact us with the part number or a sample.

MJF 3D-printed nylon automotive control knobs on a workbench - placeholder

Project details are anonymised to protect client confidentiality.

Case Study 3

A lower-cost reproduction of a high-demand Porsche interior part

Problem: A Porsche parts retailer stocked a climate control slider knob (fits 944, 968, 964 and 993) that sells steadily, because the original works loose or cracks with age. Supplied only as a full-price genuine part, its cost limited the retailer's margin and pricing flexibility on a component customers ask for constantly.

Approach

•We proposed reproducing the knob at a lower unit cost than the genuine part
•We sourced an original ourselves, reverse-engineered it and rebuilt it in CAD
•We produced a sample first and had it approved before committing to the batch

Manufacturing & materials

•Process: HP Multi Jet Fusion (MJF) for consistent, production-grade parts
•Material: nylon PA12, tough and dimensionally stable for a high-touch interior control
•Suited to repeat batches rather than one-off supply

Result

•Delivered a batch of 51 knobs within two weeks of approval
•A lower-cost alternative the retailer can resell with improved margin
•The design is kept on file, so any repeat batch is production only

Industry:: Porsche parts retail / restoration
Part type:: climate control slider knob
Method:: reverse engineering and MJF nylon 3D printing
Turnaround:: 2 weeks
Quantity:: 51 pieces

Part page: Porsche climate control slider knob

Reselling classic car parts? We can reproduce high-demand items at batch cost. Contact us.

Car connectors and parts on technical blueprints

Project details are anonymised to protect client confidentiality.

Case Study 4

Restoring discontinued connectors for a classic luxury car platform

Problem: A restoration shop needed two electrical connectors and a small mounting bracket for a high-end classic luxury model. The components were discontinued, used parts were brittle, and mismatched connectors caused intermittent sensor faults and poor harness fitment.

Approach

•Measured latch geometry, keying and pin alignment surfaces
•Rebuilt parts in CAD and standardised critical interfaces
•Completed test-fit iterations for harness routing and bracket mounts

Manufacturing & materials

•Process: 3D printing for durable, repeatable low-volume supply
•Material: engineering-grade polymers selected for durability and fit

Result

•Consistent connector fitment and reduced harness issues
•Ongoing supply so future vehicles do not rely on obsolete inventory

Industry:: automotive restoration
Part type:: electrical connectors and mounting bracket
Method:: reverse engineering and 3D printing
Outcome:: repeatable supply

Need restoration connectors or brackets reproduced? Contact us with a sample.

Flexible grommets on a workbench with measuring tool

Project details are anonymised to protect client confidentiality.

Case Study 5

Rubber-like grommets for an automotive harness update

Problem: A client needed replacement grommets to seal and protect a wiring harness route. Original parts were difficult to source and lead times were too long.

Approach

•Reverse-engineered from an original sample
•Adjusted geometry for consistent sealing and repeatable fit
•Selected a flexible, rubber-like material matched to the required stiffness range

Manufacturing & materials

•Process: resin 3D printing for prototypes and short runs
•Material: flexible elastomer-style resin

Result

•Fast turnaround and consistent fit across a short run
•Improved availability for maintenance and low-volume builds

Industry:: automotive
Part type:: sealing grommet
Lead time:: depends on quantity

Need flexible seals or grommets? Contact us with a sample.

Illustrative electrical connector photograph, not the Porsche 91161211502 reproduction

Illustrative connector photograph - see the linked part page for the 91161211502 specification.

Case Study 6

Reproducing the Porsche 14-pin connector housing 91161211502

Problem: The female 14-pin housing 911 612 115 02 appears in engine and dash wiring looms across classic Porsche models including the 911, 914, 924 S, 928, 944, 964 and 968. After decades of heat cycles, the plastic becomes brittle, locking tabs snap and the shell cracks. The reproduction addresses the damaged housing while retaining the original terminals.

Approach

•Reverse-engineered the 14-pin female housing for reproduction
•Reproduced the latch and terminal-retention features in PA12 nylon
•Specified the replacement to accept the customer's original terminals

Manufacturing & materials

•Process: Multi Jet Fusion (MJF) 3D printing
•Material: nylon PA12
•Supply: housing only - terminals are not included

Result

•A made-to-order reproduction, manufactured by Replique Labs rather than a genuine Porsche part
•The original terminals can be transferred into the replacement housing
•Published dispatch time: 10-15 working days from the order

Part number:: 91161211502 / 911.612.115.02
Part type:: 14-pin female connector housing
Method:: reverse engineering and MJF nylon printing

Part page: Porsche 14-pin connector housing 91161211502

Need a connector housing reproduced? Contact us with the part details.

Do you have a similar problem?

Whether you need a bespoke part designed from scratch or a replacement for an obsolete component, we can manufacture it.

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