Design for Additive and Reverse Engineering

Reverse Engineering & Innovative Design for Additive Manufacturing

From gas turbine design, to the visualization of complex healthcare solutions, to the development of long-lasting and lightweight automobile components, Proto Precision Additive possesses the in-house experience, expertise and technology to not only perfect the design of your concept, but also test it through accurate simulations.

Design for Additive: Part Consolidation

Re-designing traditionally manufactured sub-assembles specifically for additive manufacturing often enables significant part consolidation and part-count reductions. In designing for additive, many hard to manufacture and assemble pieces are often made in a single additively manufactured part. Designing hardware from the outset for additive manufacturing reduces part-count, assembly costs and sub-assemble related failure modes.

Proto Precision is well suited to complete additive design simplification and has self-funded a Jet-Cat combustor replacement that simplifies 25 failure-prone combustion pieces into single additively manufactured part.

Reverse Engineering: Honda 2-Cycle Exhaust

The shape of 2-stroke exhaust expansion chambers are critical to engine power output and efficiency. Expansion chamber shapes are designed with significant trial and error and tuned racing bike expansion chambers are not mass produced.

A customers requested that we duplicate the expansion chamber on his racing bike in the event that it became damaged in a crash

Proto Precision Additive successfully:

    • Created a solid-model exact copy of the expansion chamber
    • Separated the model into several printable and weldable sections
    • Created unique alignment features to ensure hardware assembled in the proper orientation and order.
    • Printed each sub-part and welded the completed expansion chamber
    • Confirmed bike fit-up

Additional copies of this specialized part are now easily obtainable and rapid iterations and testing of further refined, motor-cycle and course specific tuning is easily achievable.

Let’s Get Started

The Technology & Software We Use Throughout the Design Process:

SolidWorks Technology for 3D Design & Visualization

Proto Precision Additive uses the intuitive SolidWorks suite of design software to conceptualize, validate, transform and best develop products, parts and components. Since 1995, SolidWorks has grown substantially, successfully adding top-tier 3D Cad capabilities to its already impressive catalog. Proto Precision Additive’s in-house experts are well-experienced with all facets of this program and will use it to perfect your innovative concepts and bring them to life.



Finite Element Analysis (FEA) Software for Hardware Verfication

It is one thing to create a prototype and bring it into the world; it is another to ensure that the design can meet life requirements with real-world forces. The Proto Precision Additive team has extensive experience with Finite Element Analysis (FEA) software to ensure that hardware meets or exceeds performance targets in the areas of:

  • Mechanical Stress & Vibrations
  • Fatigue
  • Deflection and relative motion
  • Heat Transfer
  • Weight



Materialise Magics to Maximize Success Rate

The Materialise Magics print suite allows our team to convert project files to STL, repair any errors, edit the 3D design, produce airtight data and best prepare your build product for production.



Sheet Metal & Additive Manufacturing Design

Our close relationship with sister-company Proto Precision Fabrication gives us the unique ability to offer turnkey, additive manufacturing, traditional machining , sheet metal manufacturing and hybrid manufacturing solutions.

These extended benefits include, but are not limited to:

  • Rapid Sheet Metal Prototyping
  • CNC Machining (Punching, Laser Cutting & Forming)
  • Sheet Metal Part Production
  • Traditional Machining

Not only can Proto Precision Additive help you firmly understand the design process, but we can rapidly produce your part, component or product with a minimal lead-time and maximum quality.

Have additional questions regarding our additive manufacturing engineering design services and capabilities?

Contact Us