The reverse-engineering process starts with a customer need and sample component. We begin with a precision assessment and thorough documentation of the component geometry and dimensional information. Component geometry is measured electronically using a Coordinate Measuring Machine (CMM). The measurements are downloaded into an integrated CAD/CAM system with cross-section components integration capabilities. Exhaustive analysis and testing of materials is then done to establish composition, mechanical and electrical properties. Only materials that are equal to or exceed OEM specifications are used. Finally, an understanding of the form, fit, function and typical failure modes are reviewed with the customer to gain a thorough understanding of how the component is used prior to the output of drawings to be used in manufacturing the part.
Shown here is an in-tank load tap changer originally manufactured by Mitsubishi® in Japan. The project consisted of reverse-engineering and manufacturing of the complete diverter switch and resistor assembly. Reverse engineering and design work consumed over 600 man-hours including over 400 man-hours of engineering time.