Reverse Engineering Components for Fit & Function

Reverse Engineering Components for Perfect Fit & Function

We combine exceptional technologies like CT scanning and modeling and inspection softwares to re-create perfect fit and function components. For example, these gaskets were worn and cracked and the client was unable to find replacement parts. Scanning just the casting or gaskets alone would not be adequate. 

Instead, we CT scanned all three components and virtually aligned them to ensure no critical design intent was missed.

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Using Geomagic Design X’s silhouette cross sectioning feature allows us to model these gaskets using the full profile of a line even though the gaskets aren’t perfectly flat. We then use the center points of the casting to ensure bolts pass through with no interference. Then, we extrude the design cross section to the exact width of the gaskets.

Failure in the Field – Medical Instrument Carrier

Failure in the Field

This vessel is designed to hold and suspend implant screws in sterile liquid. The slots allow for various sizes to be carried using the same vessel. The vessel came to us because a screw was out of place inside the vessel prior to opening. Because of the occurrence the entire unit was quarantined for investigation.

The blue arrows point to a crack found in the seat of the carrier. The most probable explanation is that because some force is applied to hold the screw upright the seat cracked during loading. Then, during transit or handling the screw dislodged.

Versatility of CT Data

While this investigation was completed quickly, there is much more that can be learned from this dataset. For example, a common application for Industrial CT Scanning is seal and thread engagement analysis. This data can be exported to .STL for dimensional inspection, CAD comparison, and wall thickness calculations.

CAD comparison is useful to understand why the seat may have cracked. Perhaps the seat is accurate to CAD but the slots are out of position, causing stress fractures.