The part is discontinued. The OEM doesn’t sell it individually. The machine is down and every hour costs money. You’ve got a broken original or a worn-out sample, and you need a replacement that fits exactly — ideally yesterday.
This is one of the most common jobs we run. Here’s exactly how the scan-to-print workflow works, what it costs, and how fast we can turn it around.
Step 1: Scan the Part
We use structured light 3D scanning at 0.2mm resolution. The scanner projects a pattern of light onto the part’s surface and captures millions of data points, building a precise digital model of the physical object.
What comes out: A dense point cloud, converted to a mesh (STL or OBJ format). This mesh is an exact digital replica of the part as it exists — including any wear, deformation, or damage.
What scanning captures well:
- Complex curves and organic shapes
- As-built geometry (which often differs from the original drawings)
- Wear patterns that tell you where the part is stressed
- Features as small as 0.3-0.5mm
What you need to provide: The part itself, or the closest intact version you have. Clean it — remove grease, debris, paint if possible. Matte surfaces scan best. Glossy or dark surfaces may need a light dusting of scanning spray (we handle this if you bring the part in).
Time: Same day. Most parts scan in 15-60 minutes depending on size and complexity.
Step 2: Rebuild in CAD
Here’s where the raw scan becomes a production-ready part. A scan mesh is geometrically accurate but it’s not engineering CAD — it doesn’t have clean edges, defined tolerances, or parametric features you can modify.
Our CAD team takes the scan mesh and rebuilds the part in parametric CAD software. The output is a clean STEP or Parasolid file with:
- Precise dimensions matched to the scan data
- Proper tolerances on mating surfaces
- Clean geometry that’s ready for manufacturing
- Any modifications you need — thicker walls, added mounting features, material change
This is the critical step. Anyone can scan a part. The value is in the CAD conversion — turning a mesh into a real, manufacturable model with the right tolerances and modifications.
Time: 1-3 business days depending on part complexity. Simple brackets and covers: 1 day. Complex housings with multiple mating features: 2-3 days.
Step 3: Select the Material
Once we have the CAD model, we choose a material that matches or exceeds the original part’s performance.
If the original is injection-molded ABS, we might print in ASA (similar properties, better UV resistance) or nylon (better impact and wear resistance). If the original is a machined metal part that doesn’t actually need to be metal, we might print in CF-nylon at a fraction of the weight and cost.
We’ll discuss this with you. Sometimes the right call is matching the original material exactly. Sometimes the right call is upgrading it. If the part broke in service, there’s a reason — and better material selection might solve the underlying problem, not just replicate it.
Step 4: Print and Verify
With approved CAD and material selected, we print the replacement part on production equipment.
Dimensional verification: We check critical dimensions against the original scan data. If the part mates with other components, we verify those interfaces specifically. For tight-tolerance parts, we can do a comparison scan — scan the printed part and overlay it against the original scan to visualize any deviations.
Fit check: If you can send us the mating assembly, we’ll physically test fit before shipping. If not, we rely on the scan data and your dimensional callouts.
Time: 24-72 hours for printing, depending on part size and material.
Total Timeline
| Phase | Duration | Deliverable |
|---|---|---|
| Scanning | Same day | STL/OBJ mesh |
| CAD rebuild | 1-3 days | STEP file |
| Review/approval | Same day (your turnaround) | Approved model |
| Printing | 1-3 days | Physical part |
| Total | 3-7 business days | Production-ready replacement |
Compare that to sourcing a discontinued part (weeks to months, if possible at all) or commissioning a machine shop for a one-off (1-3 weeks typical, plus fixture costs).
When Scanning Isn’t Enough
Sometimes the part is too damaged to scan meaningfully. If you’ve got half a bracket or a part that’s deformed beyond its original shape, scanning gives us a starting point but we’ll need to model from scratch based on:
- The mating assembly (what does it attach to?)
- Any drawings, photos, or specs you have
- Measurements from the installation location
This adds time to the CAD phase (3-5 days instead of 1-3) but it’s absolutely doable. We’ve reverse-engineered parts from nothing more than photos and a measuring tape.
Mail-In Service
You don’t need to be local. Our mail-in workflow:
- Ship us the part (or a photo/description if it’s too large). We’ll provide a shipping address and any packaging recommendations.
- We scan and rebuild in CAD. You get the STEP file for review before we print.
- Approve the model via email. Request any modifications.
- We print and ship the replacement part to you.
We’ve done this for customers across Canada and the US. Turnaround is the same — the only addition is shipping time each way.
What This Costs
Pricing depends on part complexity, not part size. A large simple cover costs less to scan and model than a small complex mechanism.
Rough ranges:
- Scanning only (you get the mesh file): $150-300
- Scan + CAD rebuild (you get the STEP file): $400-1,200
- Scan + CAD + printed replacement: $500-1,500 for a typical part
You own the CAD file. If you need more parts later — next month, next year — we print from the same file with no additional engineering cost.
Start Here
If you’ve got a broken, worn, or discontinued part that needs replacing:
- Take a few photos and email them to us with a brief description
- We’ll tell you if it’s a scan job or a model-from-scratch job
- You’ll get a quote within 24 hours
The sooner you reach out, the sooner the machine is back up. We’ve gone from first email to shipped replacement in under a week more times than we can count.