Image 1:1: Laser scanners or Industrial CT scanning make a digital copy of the required part.
Reverse Engineering: Reducing Inventory Costs and Resolving Complex Supply Chains.
Owing to the ever-present need for faster, better and more efficient manufacturing and production
processes, advanced digital manufacturing, including
3D printing for industrial applications (or additive
manufacturing), has risen in recent years to emerge as the ideal solution.
One such effective practice is On-Demand
Manufacturing and Reverse Engineering using
additive manufacturing is a process that allows
companies to create custom parts - as many as they need, whenever needed.
It addresses traditional manufacturing issues such as
supply chain complexities, slow production cycles,
mass customisation, MOQ requirements, unavailability of spare parts and materials in particular industries and lack of physical inventory storage capacities
Imaginarium’s On-Demand, Reverse Engineering Process
Imaginarium has provided a complete ecosystem of on-demand localised manufacturing, from conceptualisation to end-use products, enabling enterprises to design better and realise products faster.
Imaginarium adopts a comprehensive design approach for spare parts production that begins with identifying the material. Our team of experts help pinpoint the base material and its equivalent to reverse engineer the sample part. Once we discover the original material, we either reverse engineer the object in the material that seems the best choice based on its functionality and durability or create a 3D model from an existing part.
Rapid services at Imaginarium can help create a satellite factory that produces the prototype and starts volume production. The internal team ensures the utmost quality control and provides post-processing techniques like anodising, chrome plating, coating & more
Client Cases: On-Demand, Reverse Engineering
During COVID-19, many industries and companies were faced with supply chain issues including the IAF. It was difficult to find spare parts and that’s when using 3D printing came into the picture. Our experts were able to create flight-certified parts in titanium and aluminium for the Indian Air Force using 3D scanning, modelling, reverse engineering and On-Demand Manufacturing.
Imaginarium Rapid specialises in engineering and manufacturing, working together to resolve complex ideas and designs while delivering quality services and parts at every step.
Priyesh Mehta, Director at Imaginarium Rapid Pvt Ltd, shared his thoughts on the benefifits of digital printing in specific industries and applications, “AM is not just for prototyping, if used correctly, and if the design is correct, the application is correct, it can be scaled up for craft production, not just mass production.”
A prominent case that involved the core of reverse engineering using 3D printing was for a UAE-based company. The Imaginarium team was asked to recreate and manufacture an obsolete water pump that was not supported by the OEMs. With no assembly blueprints or data on the part, Imaginarium was able to produce this part to near perfection.
Image 1.2: Reverse-Engineered prototype in Formlabs’ white resin (left) and final part (right)
Using reverse engineering, the elements that were used in the original object were identified and offered to create the part in an equivalent metal material – Stainless Steel 17-4 PH. Since the client needed multiple parts, we used digital 3D printing for a few parts and some parts were easier to manufacture in CNC machining. For complex geometries, especially in metal printing, the intricate cuts were machined after the part was 3D printed. The impeller was made in the Inconel 718 alloy and the prototypes were manufactured in Formlabs’ white resin.
Getting the ideal form, fifit and function in the fifirst print can be quite challenging. Imaginarium used Formlabs printers to prototype and make iterations for any corrections. 3D digital printing being accessible, compact desktop platforms can be used in-house and remotely saving on time and costs in manufacturing processes.
Imaginarium uses GE machinery and Concept Laser technology to print metal 3D parts for various applications in aerospace, defence, automotive and other industries.
Video 1.0: Client Case: Imaginarium reverse-engineered this obsolete water cooling pump in less than 30 days
The client found the process of reverse engineering using 3D printing for the US NSP/ SSP Instrument Air Compressors obsolete water cooling pumps highly beneficial. The traditional manufacturing processes could take up to 7-8 months to create this particular part with costs running into more than USD 60,000. It was neither cost nor time-effective.
Alternatively, with 3D printing, the entire process took not more than 22 days from the brief to the functional print output. Compared to its original deadline of 30 days, it was notable how quickly reverse engineering could deliver the final product, suitably impressing the end client as well:
“Imaginarium’s 3D printing work on the recent order for our cooling water pump, was quite impressive, cost-effective and had short lead times. You were provided spares that were to be printed, without any 2D CAD drawings as these were not available. The product and turnaround time of 3 weeks for the parts is quite impressive.”
3D printing and digital manufacturing act as a stop-gap solution for intense, long-running supply chain projects. Having part damage or machinery failure mid-production can affect the entire process and business goals.
One such prominent case involved a leading cargo specialist of the GCC (Gulf Cooperation Council), responsible for port terminal operations with maritime services and in free trade zones. The client brief mentioned the malfunctioning and failure of critical crane parts. The spreader arms of the crane hold, lift and move tonnes of goods continuously.
With more than 70 cranes needing around 1700 replacement parts every month, the company was looking for an affordable and durable solution. The biggest challenge the client faced was making stronger parts for its machines. The second task was manufacturing it as cost-effectively as possible. Incurring monthly part damage more than regular wear and tear added to their costs
Image 1.3: With such massive cranes, replacing damaged parts can add costs and resources
Hence, the two main problems we aimed to resolve were
Poor Tensile Strength
Frequent breakage, in particular, the leg side of the sample part used in the spreader arm of the crane.
Cost of operation
Increasing due to continuous repair, replacement and maintenance.
We had to incorporate specific requirements that enhanced the part, reduced inventory costs, replaced monthly parts, and identified potential design inclusions
Image 1.4: The 3D printed final parts in Formlabs’ Tough 2000.
Imaginarium’s solution was to replicate a sample using On-Demand Reverse Engineering and then reproduce it via 3D printing in Formlabs’ printers in Tough 2000 material.
Using compact, desktop platforms such as Formlabs helped produce in-house with on-demand iterations. Formlabs Tough 2000 material is ideal for applications that compress, stretch, bend, and impact without breaking. As one of the strongest and stiffest materials available under Formlabs, it's perfect for prototyping strong and sturdy parts that should not bend under pressure.
The original part was manufactured in ABS using injection moulding. We reverse-engineered the fifinal product in FL Tough 2000 that holds similar properties to Acrylonitrile Butadiene Styrene (ABS) plastic and works better.
And since traditional manufacturing processes can be costly, producing in-house spare parts with reliable and nonstop throughput desktop printers like Formlabs. With multiple variations of materials and powders to explore, you unlock end-use parts that are functional and aesthetic.
Our team also incorporated the concept of DfAM - Design for Additive Manufacturing - adding subtle changes that would enhance the overall function of the part in terms of strength and also fulfil the non-magnetic threader requirement.
Resolution: Reduced Inventory Costs and Skipping Complex Production Processes
With m ore advantages than traditional m anufacturing methods, digital m anufacturing is expanding in industries like aerospace, automotive, defence, healthcare and im plants, industrial and engineering manufacturing, jewellery and lifestyle sectors.
As a leader in Additive Manufacturing, Im aginarium strives towards the best-suited solution resulting from technical m anpower and advanced machinery to create applications that serve as critical components, spares and replacement parts as well as end-use parts.
Imaginarium Rapid is revolutionising the digital landscape as a service bureau of services, products and solutions. W ith multiple services from reverse engineering to vacuum casting, CNC and Tooling, we are working towards making design and digital m anufacturing accessible to all.
Connect with Imaginarium Rapid to understand how we can transform your wearables or consumer
electronics innovations to production at [email protected] or visit imaginarium.io/rapid