Reverse engineering works back from an existing component to understand the design needed for a replacement. Copy & Replace uses that process to recreate plastic parts that are broken, missing, discontinued or difficult to source.
Send photographs of the component and the equipment around it. Include both sides, any damage, the fixing points and a ruler for scale where possible. An incomplete original can still provide useful information, but missing detail may need to be established from measurements, matching parts or another reference.
Understand the features that control the fit
A housing or bracket has more to it than its visible outline. Holes, ribs, tabs, clearances and the surfaces that meet other components can all matter. Matthew will discuss the reference information needed for the job before design work starts. Photos begin the conversation; they do not replace the measurements needed for a particular fit.
Agree the design work before manufacture
Design is usually quoted first, with an estimated manufacturing price. Any design fee is agreed and paid before design begins. After design, the final manufacturing price is confirmed before you approve and pay for production. Straightforward jobs may be quoted in full from the outset.
Explain how the replacement will be used
Tell Matthew whether the part needs to flex, locate, grip, move or seal. Include expected heat, load, wear and exposure to liquids or chemicals. These details help the discussion about the recreated design and the manufacturing approach. A visual recreation alone does not establish suitability for every application.
What can provide a useful reference?
An existing housing, cover, bracket or button can provide information that is missing from drawings. A broken original may still show the interfaces and wall geometry; a matching undamaged part can help resolve an incomplete feature. If the original is unavailable, show the surrounding equipment and the references you do have. The aim is to establish the geometry required for the agreed replacement, rather than promise an exact recreation from an unclear photograph.
From enquiry to your replacement
Send photos, the equipment details and the quantity needed.
Agree the proposed work and any design fee before design begins.
Send an original only after the arrangements are confirmed.
Approve the design and final manufacturing price, then pay before production.
The replacement is made, checked and dispatched as agreed.
Work you can see
Completed work
Component housings
A damaged grey component housing recreated in white plastic for Northern Power Electric. Compare the outer profile, internal ribs and fixing features.
Often, yes. Send photos of what remains and where it fits. Matthew will discuss which missing details can be established and whether another reference or measurements are needed.
Do I need a CAD drawing?
No CAD drawing is needed to make an enquiry. Start with photographs and a description of the part. Existing drawings or CAD files can be useful if you have them.
Do I need to post the original?
Discuss the job first. Matthew will confirm what original parts are needed and provide the packing and delivery instructions after arrangements are agreed.
Can the design be changed?
Agreed changes can be discussed, but they need to be part of the quoted scope. Explain what needs to change and how the replacement should work with the existing equipment.
The quote depends on the design work, the reference information available, the features that control the fit, the manufacturing requirements and the quantity. An unclear or incomplete reference can require more work to establish the design. Design is usually quoted first with an estimated manufacturing price; the final manufacturing price is confirmed after design, before production is approved and paid for.
Why can a small plastic part need a design fee?
A small button or clip can still have internal locating details, thin walls or fixing features that need to be measured and recreated. The cost is not just the amount of plastic. Where design work is needed, the fee is agreed before that work starts. Straightforward jobs may be quoted in full at the outset.
When is recreating a part worth considering?
It is worth discussing when a suitable standard spare is unavailable or difficult to source and the rest of the equipment remains useful. The decision depends on the work required, the intended use and the cost of other options. Send the equipment details and photographs so the proposed work and price can be considered before you decide.
Have a part you cannot source?
Send photos and a short description. Matthew will discuss the next steps.
