Reverse Engineering and Additive Manufacturing

When parts cannot be sourced or restored, the remanufacturer must create them. This is accomplished via reverse engineering and additive manufacturing. The processes can be quite involved, requiring multi-disciplined skills and specific equipment. It is not a one-man effort but a team of competent engineers and technicians who know their trade and tools. 

Reverse Engineering Example – Obsolete Bracket:

Part: Mounting bracket for alternator on 1990s diesel engine
Availability: OEM discontinued, no aftermarket 
Sample: Worn bracket from donor core
Measurement method: 3D scanner + CMM verification 
Material: Cast aluminum (identified via spectrometer) 
Manufacturing method: CNC machined from billet (no casting tooling cost)
Cost per part (10 units): $45 each (vs. OEM new was $18—but unavailable) 
Outcome: Bracket reproduced. Remanufacturing continues.

Of course, reverse engineering occupies a legal gray area. Remanufacturers must navigate intellectual property (IP) law carefully.