For urgent repairs, when replacement parts are not readily available (or impossible to source)
and for studying wear of work worn or damaged equipment.

Reverse engineering is possible from a 3D scan – producing a 3D model drawing of precisely the original object being scanned. The 3D model drawing can then be adjusted to be “as new” measurements, eliminating damage seen on the original. Design improvements can be made in the CAD system, and modelling done to check for mechanical properties. From the new CAD drawing, a replacement item can be printed or machined (or a combination of the two).

In the Vortex 3D CAD system, the product design can undergo modifications for changed customer requirements, increased strength, longer lifespan, easier maintenance, lower cost manufacture, as well as aesthetic reasons for branding and marketing purposes.

From years of design experience, the Vortex 3D design team can consult on design improvements for existing (and new) designs – with a particular focus on choosing the optimum manufacturing options, with traditional CNC technologies vs. 3D additive manufacturing.

Finite Element Analysis is an added value service offered by the Vortex design team. The structural analysis tools used in-house predict a product’s real-world physical characteristics. The Vortex systems include linear, non-linear static and dynamic analysis capabilities. Strength and stiffness of 3D printed parts can be evaluated, even before the print is started – enabling design improvements for strength to be done before the first prototype is made.

For critical parts in aerospace and motorsports (to name just two industries), where weight needs to be minimised, the modelling allows radical design improvements to reduce weight while maintaining (or increasing) strength. This example of a support strut for aerospace shows the evolution of the design from the first prototype (conventional machine) to this highly organic structure – highly optimised for 3D printing in high tensile tool steel.

Your product design can be verified by producing a physical prototype From the CAD designs Vortex 3Dcan produce full size (or scale models) of designed items, for customer inspection of fit, appearance, ergonomics, packaging planning, shipping planning, assembly and disassembly considerations.

Low cost prototypes can be produced in plastic materials – for initial visual inspection and checking fit within existing structures.

High strength plastic materials, including nylon, Kevlar and carbon fibre reinforced materials can be printed in the Vortex 3D printing facility.

Vortex 3D offers printing in stainless steel, tool steel, copper and other materials, for work-ready items.

Investment casting from plastic prototypes is also offered as an option for 1-off items and small production runs.

The full capabilities of the Vortex precision engineering workshop are available for manufacturing designs larger than the capabilities of 3D printers – CNC vertical mills (up to 2m x 1m), CNC lathes (up to 2.7m x 7.5m), facing lathes (5 tonne), large planer (9 metres). These capabilities are assisted by a full fabrication workshop with certified welding services.

The Vortex design team will also advise on optimising CAD designs for volume production, including mass casting, and making the most of new and improved materials for additive manufacturing (3D printing).