A small plastic clip breaks, a rotary knob is no longer available or a holder no longer fits: often the entire device still works, but this part is missing. Reproduction in 3D printing can then be a sensible solution – provided that geometry, load and operating conditions can be reliably detected.
At 3DOrder, a replacement part remanufacturing therefore does not start with the printer, but with the examination of the existing part and its purpose. This guide shows which documents are helpful, how the reconstruction is going and where the limits of the procedure lie.
Which Replacement parts can be recreated in 3D printing?
Particularly suitable are components which can be clearly detected geometrically and whose requirements match a available printing material. Typical requests include, for example:
- covers, diaphragms and housing parts,
- brackets, guides and spacers,
- Rotary knobs, handles and controls,
- Clips, clamps and simple connecting parts,
- Adapters and individually adapted inserts,
- no longer available plastic parts for devices or everyday objects.
Whether a specific part is suitable depends not only on its shape. Equally important are forces, temperature, humidity, UV exposure, contact with chemicals and the required dimensional accuracy. Therefore, each request is examined individually.
What is needed for the reconstruction?
The most reliable part is the original part. It can be measured and assessed from multiple directions. Also, a broken part is often helpful if the fragments show the original shape.
If the original cannot be transmitted, the following basics are also suitable depending on the component:
- Photos from several directions: Front, back, pages and important details should be clearly recognizable.
- Dimensions: A ruler or slider in the image helps to determine the size. Drilling holes, spacings, wall thicknesses and connection points are crucial.
- Drawings: A dimensioned hand sketch can already be enough for simple geometries.
- Existing 3D data: STEP or other CAD data are particularly useful for technical changes. An STL file can serve as a print base or geometric reference.
- The counterpart: If the spare part has to fit into a guide, recording or shaft, dimensions or photos of the counterpart can be crucial.
On the Project request Photos and existing documents can be sent directly. The original part can also be provided by post or in person.
This is how remanufacturing at 3DOrder is done
- Clarify requirement: First, it is recorded which function the part performs, where it is used and what load it is exposed to.
- Check feasibility: Form, dimensions, material requirements and possible vulnerabilities are assessed. Not every original part can be replaced with a printed plastic part.
- Create 3D model: Based on the original, the dimensions or the existing data, a digital model is created. Missing areas can be supplemented constructively.
- Vote material and version: Material, pressure orientation, wall thicknesses and other design details are determined according to the intended use.
- Share offer: Before manufacturing, the scope and costs are transparently coordinated.
- Test Part and Manufacturing: If fit or function requires it, a test part is first manufactured and then adapted.
Further information on construction, individual production and small series are available on the page 3D Printing Services. For the purely digital reconstruction, there is also the Technical Modeling.
How is the appropriate material chosen?
Material selection is not based solely on colour or optics. For a resilient spare part, the actual operating conditions must be taken into account:
- Does pull, pressure, bending or repeated impacts work?
- Does the part get warm or is it near a heat source?
- Does it come in contact with water, detergents or other substances?
- Is it used indoors or permanently outdoors?
- Does it have to be stiff or have a certain yield?
- Which surfaces, holes and connections must fit particularly precisely?
Only from these data can a meaningful combination of material, construction and pressure alignment be obtained. A blanket material recommendation without knowledge of the component would therefore not be serious.
What determines the cost of a remanufacturing?
For a spare part, the effort often consists of two separate areas: digital reconstruction and actual manufacturing. Key cost factors include:
- completeness and quality of the existing template,
- complexity of geometry and number of functional dimensions,
- Size, material requirements and printing time,
- necessary supporting structures or post-processing,
- Expenses for test parts and fit corrections,
- desired number of pieces.
Therefore, there is no reliable flat rate for individual Replacement parts. About the Spare parts service The request is first checked and then an individual offer is made.
How to prepare a request well
A short, complete description saves queries and facilitates the first assessment. Helpful are:
- several sharp photos with good lighting,
- at least one photo with scale,
- the main dimensions and hole distances,
- a description of the function,
- Information on load, heat, humidity and outdoor area,
- the desired number of pieces,
- Information on why the original part failed.
The last point in particular is important: If the original is broken at a too thin point, the new model may be able to be adapted specifically. However, changes are always coordinated with regard to installation space, counterparts and the actual function.
Boundaries and safety-related applications
3D printing is versatile, but not automatically suitable for every spare part. Components with a safety-critical function, high temperatures, pressure loading, food contact or electrical requirements require particularly careful testing. Authorizations and legal requirements can also preclude re-production.
Moreover, a printed part is not equivalent to the original because it has the same outer shape. Material, layer structure, direction of force and structural details influence its properties. Therefore, manufacturing is not recommended for unsuitable applications.
When is the post-production worthwhile?
Additive manufacturing is particularly interesting for individual pieces and small quantities, because no separate molding tool is required. The digital model can be reused later and adjusted if necessary. This can be useful if an original part is no longer available, an individual geometry is required or several similar variants are to be created.
Whether repair, reconstruction or any other solution is more economical is only apparent after the test. The category gives an overview of already available components Replacement parts.
The next step to the right spare part
For a first assessment, a few photos, rough dimensions and a description of the function are usually enough. 3DOrder then checks which further information is needed and whether the post-production can be implemented technically and economically.