Reverse Engineering Service

Reverse Engineering Service is a practical choice when you need the right balance of performance, finish, and cost for functional parts.

Reverse Engineering: When Replacement Parts No Longer Exist

When a part breaks and cannot be sourced, most people are told the same thing: it’s obsolete. At Mitchell & Son Additive Manufacturing, we see obsolete parts differently. To us, they are simply parts that need to be reverse engineered.

Reverse engineering allows us to take an existing component—often broken, worn, or no longer manufactured—and recreate it accurately using modern CAD and 3D printing techniques. This is particularly valuable for restoration projects, legacy machinery, specialist equipment, and custom applications where traditional manufacturing would be prohibitively expensive.

The process begins with the physical part. If you can supply a sample, even if it is damaged, we can measure, model, and rebuild it digitally. Using CAD software, the part is recreated as a precise 3D model. This model becomes the foundation for manufacturing, refinement, and future reproduction if required.

One of the key advantages of reverse engineering is cost efficiency. Traditional methods such as injection moulding often require tooling costs in the region of several thousand pounds before a single part is produced. With additive manufacturing, those upfront costs are removed entirely. Parts can be produced in small quantities or even as one-offs, making the process commercially viable for individuals and businesses alike.

Material selection is another critical factor. We do not simply copy a part—we assess how it is used. If strength, movement, or repeated stress is involved, we adjust wall thickness, infill density, and material choice accordingly. ABS, PETG, and other engineering plastics each have their place, and we will advise on what best suits the real-world application.

Once printed, parts can be supplied as-produced or post-processed. Sanding, priming, surface finishing, and reinforcement options are available where required. The goal is always the same: a functional, reliable part that performs as intended.

Reverse engineering is not about shortcuts. It is about intelligent problem solving—saving time, reducing costs, and extending the life of equipment that would otherwise be written off.

Practical Reverse Engineering for Real-World Applications

Reverse engineering is most effective when it is grounded in how a part is actually used. At Mitchell & Son Additive Manufacturing, our approach is practical, not theoretical. Every project starts with understanding the function of the component, not just its shape.

Many customers come to us with parts that experience daily use—levers, clips, housings, brackets, mounts. These are not display items; they must withstand stress, movement, and environmental exposure. That reality directly informs how the part is redesigned and manufactured.

Once a sample is supplied, we digitally recreate the component in CAD. This is not a rough approximation. Dimensions, tolerances, and fit are carefully considered to ensure the new part integrates seamlessly into its original assembly. Where weaknesses existed in the original design, improvements can be made discreetly without altering compatibility.

Material choice plays a significant role. For indoor mechanical components, ABS may be entirely suitable due to its strength and rigidity. For outdoor or UV-exposed parts, PETG or alternative materials provide better longevity. These decisions are discussed upfront so there are no surprises later in the process.

Unlike injection moulding, 3D printing allows us to control internal structure. Infill percentages are selected based on how much force the part must withstand. A decorative item does not need the same internal density as a load-bearing or moving component. This ensures the final part is strong enough without unnecessary cost.

Reverse engineering also future-proofs your project. Once the CAD file exists, additional parts can be produced quickly without repeating the design phase. For businesses, this means reduced downtime. For restoration projects, it means long-term sustainability.

Our role is not just to replicate a part, but to restore function and reliability. Reverse engineering offers a modern solution to problems that traditional manufacturing can no longer solve efficiently.

From Broken Part to Working Solution

A broken part does not always mean the end of a project. In many cases, it is simply the starting point for reverse engineering.

At Mitchell & Son Additive Manufacturing, we regularly work with components that are cracked, snapped, worn, or partially missing. As long as enough reference exists, we can rebuild the geometry digitally and produce a functional replacement.

The workflow is straightforward but precise. A physical sample is analysed and recreated in CAD, producing a fully printable 3D model. This model can be retained by the customer if required, giving full transparency and long-term flexibility.

Where reverse engineering truly adds value is in optimisation. Older parts were often designed around manufacturing limitations that no longer apply. Using additive manufacturing, we can strengthen stress points, refine tolerances, or improve material performance without changing how the part fits or operates.

Cost is a major consideration for most customers. Injection moulding and CNC machining are rarely viable for low volumes. Reverse engineering combined with 3D printing removes tooling costs entirely, allowing production runs of one, ten, or fifty parts without financial penalty.

Post-processing options are available where appearance or surface finish matters. Parts can be sanded, primed, reinforced, or sealed depending on the application. These options are always discussed transparently so customers can balance cost against finish and durability.

Reverse engineering bridges the gap between old problems and modern solutions. It keeps equipment running, projects moving, and costs under control—without compromising on performance.

Reverse Engineering as a Cost-Saving Manufacturing Strategy

Reverse engineering is often viewed as a last resort. In reality, it is one of the most efficient manufacturing strategies available for low-volume and legacy parts.

At Mitchell & Son Additive Manufacturing, we use reverse engineering to eliminate unnecessary tooling, reduce lead times, and give customers control over their parts again. Whether the original supplier no longer exists or minimum order quantities are impractical, reverse engineering offers a direct alternative.

The process begins with digitisation. A physical part is converted into a precise CAD model that can be printed, modified, or stored for future use. This digital asset becomes a long-term solution rather than a one-off fix.

Additive manufacturing allows us to match strength requirements accurately. Parts that experience movement or load can be printed with higher infill and reinforced geometry, while non-structural components can be produced more economically.

Material selection is handled pragmatically. We advise based on environment, wear, and expected lifespan rather than defaulting to a single material. This ensures performance without over-engineering.

For businesses, reverse engineering reduces downtime and dependency on external suppliers. For individuals and restoration specialists, it makes previously impossible repairs achievable.

Reverse engineering is not about copying—it is about continuity. It ensures that a single broken component does not render an entire system unusable.

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