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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.
CNC lathe machining a small brass ring - placeholder for Fiat 1100 water-pump seal case study

Project details are anonymised to protect client confidentiality.

Case Study 2

Reproducing 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 part has been out of production for decades. It cannot be ordered, 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

  • •Reverse-engineered the seal assembly from an original sample
  • •Measured the sealing faces and interfaces and rebuilt the geometry in CAD
  • •Split the assembly by process, since it combines several materials

Manufacturing & materials

  • •Process: CNC turning for the metal elements, casting for the flexible element, then assembly
  • •Materials: brass upper ring, lower ring and body; carbon slip ring; rubber bellows; stainless-steel spring
  • •Sealing element matched to the application rather than copying perished original rubber

Result

  • •Delivered as a consistent batch of 50, dimensionally checked before shipping
  • •A dependable stock so the car runs without sourcing one seal at a time
  • •Design kept on file, so any future batch is production only
Industry:
automotive restoration
Part type:
water-pump seal assembly
Method:
reverse engineering and CNC turning
Quantity:
50 pieces

Part page: Fiat 1100 water pump seal 882723

Have an obsolete part you can't source? Contact us with 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.
Measuring a metal component with calipers during inspection

Project details are anonymised to protect client confidentiality.

Case Study 6

Reverse-engineered metal protective component made by CNC machining

Problem: A metal protective component was required to restore function in an automotive assembly. The original part was not available through standard channels.

Approach

  • •Measured and modelled from an original part
  • •Defined critical interfaces and tolerances to ensure correct assembly
  • •Produced prototypes, then finalised a repeatable machining plan

Manufacturing & materials

  • •Process: CNC machining
  • •Material options: aluminium or stainless steel depending on operating environment and corrosion requirements

Result

  • •Drop-in fit based on the original geometry
  • •Reliable supply for service and small-batch needs
Industry:
automotive
Part type:
metal protective component
Method:
reverse engineering and CNC machining
Have a metal part you need reproduced? Send a sample and we will advise the best route.

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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