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Cement Floor

Reverse Engineering

Reverse Engineering

The contacts provided by 35 years of experience are an invaluable benefit to our customers. These partners-in-business expand the abilities of LMP to provide you with a superior finished product.

LMP can produce two-dimensional drawings and solid surface model data from your existing broken or obsolete part. From these files actual cast or machined replacement parts can be manufactured.

  • LMP can rapidly replace your broken or obsolete machine parts.

  • Coupled with Direct Mold Milling, cost and time can be greatly decreased for individual cast repair parts.

Reverse Engineering

Example Parts


Applications for Reverse Engineering
Reverse engineering is used to replicate broken, obsolete parts and produce replacements for out-of-production parts. LMP has the ability to:

  • Create drawings from an existing part

  • Generate 3D CAD models from an existing part

  • Create short run/low volume parts from an existing part

  • Generate production tooling for a higher production volume runs based on an existing part

  • Create 3D CAD models from a 2D blueprint drawing

Reverse Engineering Methods
Optical Scanning - With the use of an optical scanner we capture a digital shape of your part that may not have current or sufficient design documentation or that may require 3D CAD data for modern manufacturing methods. 3D CAD models can be easily updated for changes in the design. There are virtually no limitations to part size that can be scanned due to the flexibility and mobility of the camera system. Please see detailed information on our Optical Scanning Process listed below.

Manual Machining - LMP has the capabilities for Milling, Turning, Drilling, Welding and Bending.

CNC Machining - We can develop and modify your part files. We can generate tool paths from this 3D CAD and machine customer tooling with detailed precision using one of our CNC machining centers.

Direct Molding - LMP will mold off of the existing part if it is intact and the geometry is conducive to this process. Extremely intricate parts requiring core boxes, pulls and other elaborate features cannot have a mold taken directly from the part. Direct molding is best for applications that do not require tight tolerances or elaborate vertical detail.


Stereolithography (SLA)

Direct Mold Milling (DMM) - Direct Mold Milling involves the carving of the mold directly into a sand block. This bypasses the traditional sand casting mold making steps of creating a master pattern and placing that pattern in sand to create a mold. Both the mold and the core can be machined into the sand block as well as the standard mold components: sprue, risers, gating system and pouring cup. LMP has worked with other industry leaders to develop this emerging method of manufacturing. Direct Mold Milling (DMM) enables us to eliminate hard tooling, and the time necessary to produce it.

With DMM we can significantly reduce the time and cost to sample a cast part. Coupled with reverse engineering, we can manufacture single replacement parts, or sample prototypes, without a commitment to the time and cost requirements of hard tooling. Benefits of this process include:

  • Direct Mold Milling can significantly reduce the time to produce an actual cast part. With customer-supplied solid surface data, molds and complex cores can be ready to pour in as little as twenty-four hours.

  • LMP has the ability to produce a mold directly from your two-dimensional files or prints. With our SURFCAM software, we can even help you design your part.

  • It is not recommended for thin wall applications but can provide good tolerances and repeatability due to our in-house CNC machining equipment.

Tooling Features
LMP designs for and/or manufactures all necessary features into reverse engineered parts, patterns and molds such as:

  • Gating

  • Risers

  • Small tolerance, intricate patterns

  • Labeling/Logos/Engravings

  • Cast thread detail

  • Zero-draft cores

  • Cooling fins

  • Prep/pin/bolt locations (for large patterns/tools)

  • Pouring basins

  • Core boxes

  • Shell boxes for pouring sprues

  • Manual/Pneumatic Ejectors

  • Manual/Pneumatic Pulls

  • Manual/Pneumatic Core Systems

  • Investment Drawers

Available Part, Pattern, Tooling and Mold Materials
Reverse engineered patterns and tooling can be made from a variety of materials including wood, aluminum, iron, steel, plastics, urethanes, 2 part epoxy resins and foundry tooling boards.

Production molds can be reverse engineered and manufactured from aluminum. Replacement parts can be made from ABS plastics, polyurethane foams, stainless steel, aluminum, wood, wax and various epoxy resins.

Machining Tolerances
LMP has the ability to produce your smallest most intricate parts, molds, and models with tolerances +/- .005” using conventional and CNC machine tools.

Production Volume
Reverse engineering is typically for single or low volume replacement parts, however production run tooling can be made for larger amounts.

Direct Mold Milling requires no hard tooling, it is used for low volume applications. Usually for proto

Preferred Drawing Submission
We support DWG, DXF, IGES, DSN, SCPRT, x_t and other customer files utilizing our Surfcam software and can arrange for file conversion of any program we do not currently support.

LMP uses Surfcam CAD/CAM Software for all tooling design and fabrication.

In-House Equipment
Motionmaster 60 x 60 x 30 CNC 5-axis router (2)
Thermwood 60 x 120 3-axis CNC
Freyer 30 X 60 X 30 3-axis Vertical Machining Center
Cintimatic 18 X 30 X 18 3-axis Vertical Machining Center
Wadkins Vertical Turning Center

Optical Scanning Process

Step 1: Scanning   


The operator performs an Optical Scanning of an existing steel fabricated mold. During the process light patterns are cast across the surface providing a 3-D computer model of the part.

Optical Scanning Process - Step 1

Step 2: Image Compilation   


Several “shots” are taken and overlaid to create a solid computer model of the internal detail of the fabricated mold.

Optical Scanning Process - Step 2

Step 3: 3D Rendering  


A solid computer model is gradually developed which perfectly replicates the detail contained in the subject part.

Optical Scanning Process - Step 3

Step 4: Mold Fabrication


This wood model, CNC machined on our 5-axis high speed router, is a perfect replica of the internal mold detail captured by the optical scan. It is representative of a full scale part manufactured by the existing steel mold.

Optical Scanning Process - Step 4
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