Reverse Engineering - Safety Critical Train Component

London Underground main contractor Tubelines had come to the end of their stock of a safety critical component fitted to underground trains manufactured in the early 1970’s. The “Dead mans handle” was originally designed to be an aluminium machined casting by which a driver can operate the train and which would automatically stop the train should the driver become unconscious in any way. J H May were supplied with a cast and machined example known to be correct and not worn.

Original part 3d laser scan/3d CAD preparation

The first stage was to undertake a 3D laser scanning process of the component.
Stage 2 involved measuring the piece with our co-ordinate measuring machine (CMM).
Stage 3 convert the 3D surface data that was captured with the laser scanner into a usable 3d format.
Stage 4 import the file into our Solidworks 3D CAD design software, add the measurement data captured from the co-ordinate measuring machine and create the final manufacturing cad data in IGES format and drawings in DXF format.
Stage 5 CNC machining from solid aerospace grade aluminium and hard anodising to complete the project.

Original part 3d laser scan / 3d CAD preparation		3d CMM inspection

This was the first time that our client had specified a reverse engineering project which employed a combination of 3D laser scanning , CAD design and CNC Machining technology. They were extremely happy with the results and plan to use the process in the future as there spare part stock levels are depleted. We expect to be busy in the coming years as the rolling stock is already beyond its intended life and is expected to be in service for another 7 to 10 years.