Technical Case Studies

We Make the Parts You Can’t Find

A look at some of the work we’ve done: worn parts rebuilt, existing designs improved, and custom parts made to order. Each project shows what was needed, how we approached it, and how it turned out.

Have a part like one of these, or something completely different? We’d like to hear about it.

Co-Fabricating a Dual-Material Polymer Impeller Assembly

Reverse Engineering | Prototyping | Industrial Polymer Additive Manufacturing

Replacing a machined stainless steel shaft and molded polymer impeller with an integrated composite polymer assembly, developed as a field-use candidate.

Original: polymer impeller molded onto a stainless steel shaft

Re-engineered: dual-material composite, printed with industrial FFF

The Challenge

The original assembly was a molded polymer impeller built around a precision-machined stainless steel shaft. Making it took several separate operations and suppliers: CNC machining of the shaft, machining for polymer keying, injection molding the impeller onto the shaft, then drilling and tapping for set screws and machining the seal area.

We approached it as a reverse-engineering and design-for-manufacturing problem, not a copy job: understand what the assembly needs to do, then redesign it around material behavior, load path, chemical and temperature exposure, and what industrial FFF can do.

The Re-Engineered Assembly

The impeller body is printed in carbon fiber-filled polypropylene for chemical compatibility, temperature capability, and harsh environments. In the same print, a stiffer carbon fiber-filled polyamide composite is co-fabricated into the core, forming the shaft and extending into the hub for rigidity, internal support, and mechanical engagement between the two materials.

Heat-set threaded inserts in the printed shaft take the set screws, removing the drilling and tapping step. Replacing the stainless shaft also reduces rotating mass, which lowers the load on the drive, shaft interface, bearings, and seals during startup, stopping, and speed changes.

Original stainless shaft before molding

Re-engineered dual-material assembly

Original

Machined stainless steel shaft
Molded polymer impeller
Drilling and tapping after molding
Seal-area machining
Several supplier-dependent operations

Re-Engineered

Carbon fiber-filled polypropylene impeller body
Co-fabricated high-stiffness composite shaft
Integrated threaded inserts
Reduced rotating mass
Fewer secondary operations

Result

The final prototype was developed as a field-use candidate, evaluated for fit, function, stiffness, material behavior, manufacturability, and rotating mass reduction. A multi-step stainless steel and molded polymer component became a single co-fabricated dual-material composite part.

Customer-specific details, proprietary dimensions, interface geometry, and print strategy have been intentionally omitted.

Walnut Blasting Adapter for BMW N54 and N55 Engines

Production | Material Upgrade | Made to Order

An intake port adapter used for walnut blasting carbon buildup from the intake valves on BMW N54 and N55 engines, produced to order in an industrial-grade composite that stands up to repeated use.

The Request

A customer asked whether we could make this adapter in a material that would hold up in real use. Adapters like this are commonly 3D printed in standard materials such as PETG or ABS, which wear and break under the repeated impact of walnut shell media. The customer needed a part that could take that abuse job after job.

Our Approach

We produce the adapter to order in carbon fiber reinforced nylon (PA-CF), an industrial-grade engineering composite chosen for its toughness, stiffness, and abrasion resistance. Parts are made one at a time or in batches as orders come in.

Based on the N54 Vacuum adapter for Intake Port Media Blasting by sstory0626, licensed under CC BY 4.0. Modified and produced by REV2 Industrial Solutions.

Pump Casing Redesign

We reverse engineered an existing pump casing, then redesigned the discharge volute for better flow before producing the new casing.

1. Original part
The casing as received.

2. CAD model
Geometry recreated and the discharge volute redesigned.

3. REV2 replacement
The redesigned casing, printed and ready for fit-up.