What we do?
At MD Design & Automation, we design and manufacture many types of parts, for many applications and markets, using the latest technology in re-design and reverse engineering. We have the ability to replicate, and often improve a product or part, by utilizing our years of experience, combined with our extensive knowledge of available materials.
We have the ability to create one-of-a-kind replacement parts for customers' machines, parts that may be no longer in production or in circulation. We can also reverse-engineer worn out or broken parts and produce new parts with a drawing for future reference. In addition, we redesign parts made as castings to be made as weld ments, which gives the advantage of a short lead-time and a more repair-friendly design.
How we do it?
Our team works with state-of-the-art 3D modeling software, to define and calculate the dimensions of the original part. Next, drawings of re-engineered parts or prototypes can be emailed, faxed, or physically delivered to you before any machining is performed.
Once you and our team thoroughly inspects the drawing and/or prototype, we'll manufacture the part to your stringent specifications.
Case Study :: Reverse Engineer Wood Concrete Mold
A client came to us with a problem. For years, they had been using an old wood mold, to make concrete parts. They had poured concrete into the mold to create this decorative part for many years, but the water and concrete had taken its toll, and had degraded the mold to a point where it was unusable. Our team developed an affordable solution to create a new mold, using new, more resilient materials that in the end created a better end-product, one that was easier to use and to maintain.
Read More Below.
Client Provided Original Wood Mold (Concrete Form)
The client provided us with two (2) halves of an old wood mold, used to create a concrete part. As you can see, the mold was falling apart with age and use, and was no longer providing a high quality product for their customers. In Step 1 of our process, we gathered information, discussing the wants, needs, and concerns with the client. Understanding the client needs, we informed the client that we could indeed reverse engineer the antique, weathered and well-worn mold. We quickly drafted a plan, and agreed to terms that fit within their schedule and desired budget.
Experience & Technology At Work
The MD Design & Automation team seamlessly models the actual, antique wooden concrete mold, using a Brown & Sharp Chameleon 765 Direct coordinate measuring machine or CMM. This model is then scanned with the CMM and imported into CAD to produce a digital copy of the original part. The CAD data can now be imported into a CAM package for machining. Importing the data back into PC-DMIS cad++, the digital file can now be used as a "master", to inspect the final machined part.
Creating The Rough Form
As stated above, once the data is obtained through the CMM technology, we are able to machine a rough form of the desired part, in this case, the concrete mold, using one of our Haas VF2 CNC machines. For this project, we made the material recommendation to use 6061-T651 aluminum, for the fact that 6061-T651 aluminum is great to machine, is resistant to oxidation, and the release properties it added to the concrete the client was using, and will last a lifetime. For this reason, the client will enjoy many years of service with this unique mold. In the event the client desires a replacement or development of a second mold, the part is once again replicated with the data already obtained.
Final Reverse Engineered Concrete Mold
We finish the part by machining to the final tolerances, and deliver the product to the client, on time, and on budget. Upon project completion, we evaluate the job, and determine what aspects of the project went as planned, and where improvements could be possibly made. We complete this process to continuously improve the services we offer our clients, and the products they use to run their businesses smartly and efficiently.
The Finish Product
The resulting concrete product has been in use for several years now, sitting atop of several hundred light poles across the Midwest.