Reverse engineering of new gears and housing for trams
Customer: Västtrafik AB, Sweden
Project tasks
- Measuring of the gearbox housing
- 3D modelling and technical drawings
- Material definition
- Definition of applicable standards
- Risk assessment
- Criteria for quality control
Our approach
PROSE applied a hybrid reverse-engineering method that combined mobile 3D scanning, mesh processing, and feature-based CAD modelling to reconstruct the gear housing. In parallel, we coordinated with the third-party supplier Zoerkler to perform precision gear measurement, material analysis, and hardness verification.
All interfaces, tolerances, and functional surfaces were systematically cross-checked against the physical components and validated through a structured CSM-RA risk assessment.
Based on these inputs, PROSE established updated 3D/2D documentation and a technical specification defining material, heat treatment, tolerances and surface-finish requirements in accordance with railway safety and documentation standards.
Customer benefit
The long-term availability of spare parts is ensured through updated and complete technical documentation that enables reliable future manufacturing of spare parts. This significantly reduces the risk of obsolescence for the parts involved.
Thanks to PROSE’s hybrid reverse-engineering approach, combining mobile 3D scanning, mesh processing, and feature-based Computer-Aided Design (CAD) modelling, the technical documentation was delivered in a time-efficient manner. At the same time, we ensured an uncompromised level of safety and quality compared with the current gearbox parts.
Throughout the project, PROSE maintained continuous dialogue with all involved actors to achieve solutions that meet the customer’s needs, supported by our independent position and broad engineering expertise.
