When a business from the materials industry couldn’t buy new parts for their 30-year old production line, they approached Lyndhurst Precision to design and manufacture new ones.

We have a strong background in reverse engineering and building bespoke parts that are no longer available on the market, making our team a natural fit for this project. We began the project by conducting an on-site review of the existing assembly at the customer’s facility. This is an important part of the process as it allows our design team to understand not only how the parts work, but also the conditions in which they operate. This is useful in the design process as it helps us choose the most suitable materials, treatments and techniques.

As the current parts were large, bulky and expensive to maintain, we proposed a new modular design. Each module can be easily removed, reducing the cost and complexity of maintenance, installation and ordering spare components. As the machine operated in harsh environments, we also offered some treatments and materials that would improve the component’s resistance to corrosion and wear for optimal performance. Our customer approved this initial concept design and, after a design and manufacturability review, the project moved to our shop floor for production.

We manufactured the part fully in-house, utilising our waterjet, CNC machining centres and fabrication welding capabilities. We also inspected each part in-house to check adherence to our detailed technical drawings before assembly. After an initial trial build, the machine was treated before its final assembly. After approval from the customer, the new parts were delivered to their facility.