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Fun @ Work

At work I have the pleasure of people walking up to me with hand drawn blue-prints of items they would like fabricated.  I call these “Prototype” projects.

I’m also handed existing objects that we may have created at one time that need modifications or are broken and need to be remade (and there are no existing CAD files for).  I call these “Reverse Engineering” projects.

Using 3D CAD software, I build the project so parts can be cut, bent, drilled, welded, sandblasted, powder-coated, assembled, etc…  It’s a lot of fun.

So, what exactly do I mean by “Prototyping”?

A prototype is anything original that hasn’t been built before.  A TV stand may not be original, but a TV stand that you designed to fit in your living room is.

Here’s a recent drawing that I was handed.  Joe (The Hander) explained it to me for a minute, I asked a few questions, and less than an hour later I had created the parts, assembly file, drawing file, DWGs, and emailed it all to Joe for approval before he created nesting files for the plate laser and printed off the drawings for the welders to fabricate it.


DVR Flat Screen TV Stand - Prototype Hand Drawing

DVR Flat Screen TV Stand – Prototype Hand Drawing

DVR & Flat Screen TV Stand - assembly drawing

DVR & Flat Screen TV Stand – assembly drawing

Flat Panel TV & DVR Stand, 1.5" Square Steel Tubing, 1/8" Steel Plate, Weldment, 46" wide, 19" deep, 36" height

Flat Panel TV & DVR Stand

And what about “Reverse Engineering”?

Most of the time I don’t have to deal with extreme-precision pieces, other than CNC Machine parts, meaning: as long as it’s within a 16th or 32nd of an inch, it’s good.  But sometimes I have to reverse engineer something and have no idea if it was originally designed in metric or standard, and when I’m measuring it, my micrometer may say a length is .129″ or 3.277mm.  So is it supposed to be 1/8in, or is it 3 1/4mm?  Or am I not squeezing the object tight enough/too tight with my micrometer?  Should I consider the fact that it’s a plastic piece that may flex or deform as I measure it, or consider that it’s powder-coated metal and the paint layer can add to a measurement?

Then I tell myself to chill and just take measurements and type them in. Someone else will fabricate the part according to print, and if it doesn’t work, then we’ll figure out what needs to change and move ahead accordingly. 

Here’s one of those tough-to-measure projects.  It’s a piece of pliers used to tag livestock animals’ ears.  It is manufactured in plastic, but the person who uses it breaks it often (and it’s inconvenient and expensive enough to replace) and asked if we could make a metal version so it would be more durable.  I didn’t have the whole apparatus, just the little piece, so I was unable to completely understand how it operated mechanically.  I had to create a model in SolidWorks so I could make a drawing dimensioned to 4 decimals for the CNC machine operator to mill the part.


Set Screw Pliers Part, Livestock Tagging Tool,

Set Screw Pliers Part, Livestock Tagging Tool

Set Screw Pliers Part, Livestock Tagging Tool

Set Screw Pliers Part, Livestock Tagging Tool

Set Screw Pliers Part Drawing

Set Screw Pliers Part Drawing

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One Response to Prototyping & Reverse Engineering

  1. Jeff Kaith says:

    With Reverse Engineering services, it will be possible for you to make crucial changes in your design which you think is not serving the purpose in any way by being either expensive, un-machinable, too strong or weak, unattractive in aesthetics (looks), material being rare or depleted or many other problems specific to it.

    Product redesigning is a core application of Reverse Engineering process. In Product redesigning, we know you are looking for superior and modified designs of your existing product which is being manufactured, or hasnt gone in the workshop yet.

    You have a design, and you know that it is the perfect design of the product you will manufacture. But, the problem is about making things happen! It is difficult at times, to manufacture a product because of the set-up needed for machining, assembling, heat-treatment, welding, molding and all sorts of mechanical operations.

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