REVERSE ENGINEERING AS A SOLUTION IN THE RESTORATION OF A UNIQUE HELMET

The owner of a unique motorcycle helmet, Katsuya Tanabiki, used reverse engineering to fix up the broken spare part of the shield notch that is no longer available on the market. His project is the perfect occasion to use modern technology to produce the spare part fast and cost-efficiently.

unique-helmet-reverse-engineering

DESIGNING AN IDEA – 3D SCANNING, REVERSE ENGINEERING, 3D PRINTING

At first, he set up his plan. He imagined that the part that required repair would first be scanned with a 3D scanner, the data imported into a 3D program, and with reverse engineering, he would make a whole new piece model. He would simply use a 3D printer and make a duplicate.

In the case of a simpler shape, as we did last time in the case of the bicycle pump holder, the first part, 3D scanning could be replaced with simple measurements, but this type of piece has a more complex shape, which requires the use of 3D scanning.

shield-notch-before-reverse-engineering

3D SCANNING

Firstly, the shield notch was removed from his helmet and cleaned. Then 3D scanning took part. He used his Shining 3D handheld 3D scanner, the EinScan Pro 2X, which he has been using for a long time and is very satisfied with. He placed the piece on a turntable and attached the 3D scanner to the stand. By rotating the panel, he thus obtained all the necessary data and a sufficiently accurate scan for his needs during the 3D scan. Everything was ready for the second phase.

3D-scanning-of-the-shield-notch-of-motorbike-helmet

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DATA PROCESSING AND REVERSE ENGINEERING

The results of the scan Katsuya imported into a 3D program and began processing. As said, the scan was accurate enough, so he was able to tackle this task right away and start creating a CAD model with reverse engineering.

Based on a large number of points, the 3D program has already roughly drawn a 3D model, which Kasuya only had to adjust in detail. Due to wear and tear, the shield notch has lost its original form, so knowledge of shapes and foresight is also required. With a few tweaks, Katsuyu was able to accurately recreate the shield notch with reverse engineering. Only 3D printing of the CAD model is required now.

CAD-model-of-the-shield-notch-before-reverse-engineering

3D PRINTING

For the final phase, it was only the turn of 3D printing of the created CAD model. The article did not present which material and 3D printer Katsuya used. In 3Way, we would use the smallest 3D printer, due to the size of the piece. This means the FlashForge Adventurer 3. When it comes to choosing the material, we would reach for ABS filament of any color.

printed-3D-model-of-the-shield-notch-with-3D-printer
printed-3D-model-of-the-shield-notch-with-3D-printer

What would we use for 3D printing of the shield notch?

THE PROJECT WAS SUCCESSFUL

In the end, Katsuya was satisfied with the implementation of the project, as he managed to recreate a duplicate piece with reverse engineering, which is otherwise no longer possible to get on the market. 3D scanning, model processing with reverse engineering, and 3D printing, took him only one hour. It is definitely a time and cost-effective solution, but it is necessary to have enough knowledge to be satisfied with what has been created.

the-shield-notch-reverse-engineering
the-shield-notch-reverse-engineering
the-shield-notch-reverse-engineering

All in all, it is proof of the connection between 3D scanning, reverse engineering and 3D printing, which are widely used as relatively new technologies. Katsuya loves 3D technology and will use it in future similar projects.

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