Go Ahead London - Casing Reverse Engineer
Combining design engineering & 3D printing
brief
Go-Ahead London encountered a recurring issue with worn and broken casings in their bus fleet modules.
Faced with the costly alternative of replacing entire units, we collaborated with AME-3D to reverse engineer and 3D print the damaged part, providing a cost-effective, durable solution.
The casing that held the plugs in place on several modules was worn out, with some even snapping, leading to operational difficulties. Replacing the entire module was an unnecessarily expensive option. They needed a solution that would restore the modules without incurring the high cost of full replacements.
We worked closely with AME-3D to reverse engineer the worn casing and create a replacement part. The process involved:
3D Scanning: We scanned the broken parts to capture their dimensions accurately.
CAD Design: Our design team created precise CAD models to replicate the part’s original dimensions.
Module Adaptation: The top of the old, worn casing was carefully cut out of the module. We made tweaks to the CAD to ensure the new part would fit flush with the existing module.
SLS 3D Printing: Using Selective Laser Sintering (SLS), we printed the replacement parts. This method produced strong, durable parts that would withstand long-term use.
By scanning the broken part, creating precise CAD models, and using Selective Laser Sintering (SLS) for production, we were able to create robust replacement parts that restored the functionality of the modules
This project showcases the power of engineering innovation and 3D printing to deliver practical, cost-effective solutions for complex problems.
If you’re facing similar challenges with worn parts or need custom engineering solutions, reach out to us today to discover how we can help you save costs and extend the life of your equipment.
If you're interested in collaborating with us or exploring how we can assist you, please get in touch.
If you are interested in continuing this conversation, please get in touch at hello@biild.co.uk.