Reconstructing Damaged Parts through 3D Scanning and Printing

Overview

When a small yet crucial plastic component becomes damaged, sourcing a replacement can often be time-consuming, expensive, or simply impossible. Traditional reproduction methods — such as manual measurement and CAD redesign — frequently fall short in accuracy and efficiency.

Canadian engineering company MyEngineering faced exactly this challenge. Instead of relying on conventional manufacturing, they adopted an innovative digital workflow powered by SCANOLOGY’s SIMSCAN 3D scanner and Quicksurface reverse-engineering software. By integrating high-precision 3D scanning and additive manufacturing, MyEngineering successfully reconstructed damaged plastic components with exceptional speed and precision — achieving results that conventional methods could not match.

Challenges

The main challenge was to recreate a damaged plastic part that was difficult to purchase or reproduce through conventional manufacturing.

Key difficulties included:

• Capturing fine detailsof small, smooth, and complex surfaces
• Repairing and aligning scan datawhere the part had been physically damaged
• Reconstructing the original geometryto ensure accurate 3D printing and assembly compatibility

The part measured approximately 20 cm in length, made of non-reflective plastic, and featured fine curvature and detail — making it difficult to measure or reproduce using traditional tools.

Solutions

To overcome these challenges, MyEngineering implemented a streamlined digital workflow using SCANOLOGY’s SIMSCAN 3D scanner, a metrology-grade portable 3D scanner designed for small parts and confined spaces.

1. Scanning– The damaged components were scanned in batches, each taking only about five minutes per part. SIMSCAN’s compact design and powerful blue laser system enabled effortless, high-precision scanning without any surface treatment.
2. Data Processing– The scanned data was imported into Quicksurface, where engineers used intelligent surface reconstruction tools to repair incomplete geometries and rebuild missing sections. The process of restoring the original design took less than ten minutesper part.
3. 3D Printing– The reconstructed models were then 3D printed, producing high-quality, functional replacement parts that fit perfectly within the original assemblies.

Watch the Process in Action

See how MyEngineering leveraged SCANOLOGY’s SIMSCAN and Quicksurface to scan, reconstruct, and reproduce the damaged part in this 8-minute step-by-step demonstration.

Results

By adopting SCANOLOGY’s 3D scanning and reverse-engineering workflow, MyEngineering achieved outstanding results:

• Fast and accurate data capturewithout any powder or surface preparation
• Automatic repair and reconstructionof missing features with minimal manual modeling
• Dramatic reduction in turnaround time— from several hours down to just minutes
• Perfect fit and functionalityof replacement parts within the existing assemblies

This approach not only streamlined MyEngineering’s workflow but also reduced cost, eliminated third-party dependencies, and enhanced flexibility in low-volume part reproduction.

Conclusion

The collaboration between MyEngineering and SCANOLOGY showcases the transformative potential of digital manufacturing technologies.
By combining SIMSCAN’s ultra-compact, metrology-grade scanning capabilities with Quicksurface’s intelligent modeling tools, the team demonstrated how 3D scanning and printing can revolutionize part reconstruction and maintenance.

This case study proves that SCANOLOGY’s 3D solutions are ideal for fast, precise, and efficient reproduction of small and complex components — empowering engineers and manufacturers to turn challenges into opportunities.

See it in action: Watch the full 8-minute demonstration