New Reengineering Process for Parts: What You Need to Know Before Getting StartedBlog Post

When a critical machine part fails, you don’t have time to chase down overseas suppliers or wait weeks for OEM replacements. That’s where the reengineering process for parts comes in, especially when you don’t have a print, the part is obsolete, or the cost is sky-high. As Andy O’Connor explains, “the customer has a part that they need for some type of machinery… and they obviously need to figure out how to get that part.”

At Truco, reengineering isn’t guesswork. It’s a precise, multi-step workflow that blends 3D scanning, specialized software, and CNC machining to deliver accurate, repeatable replacement parts. If you’ve never been through the reengineering process for parts before, here’s exactly what to expect and how to make sure your project is set up for success.

What Truco Needs From You First

Before the reengineering process for parts even begins, Andy stresses the importance of gathering the right information:

• Material: “We want to know what material it is, or their best guess.”

• Function: “We want to know… How critical is this part to doing its job? What does it do?”

• Quantity: “How many are you looking to make? Are you looking to make 10, 12 parts?”

• Replacement cost: “What is the replacement cost? Being upfront about what the replacement cost goes a long way to determining the best path”

These questions help determine if reengineering makes financial sense. As Andy puts it directly, “These things are $800… can you scan them, make eight of them, and save us some money? Yeah, we can. But if this thing costs $80… no, just buy them for $80.”

Being transparent saves everyone time and gets your project moving faster.

Step 1: Scanning the Original Part

Once the part arrives, the reengineering process for parts begins with a precision 3D scan.

Andy describes the setup:

• The part is measured with calipers.

• It is placed on a Zeiss GOM Scan One turntable.

• Andy’s partner, Mike, applies “little targets all over it” so the camera can track each angle.

• The blue-light scanner captures “a dozen scans… sometimes 60 scans” depending on size.

The scanner is so sensitive that Andy recalls Mike saying, “I’m disconnecting it from the table,” because the software was picking up “a piece of dust.”

This raw scan is only the beginning.

Step 2: Cleaning the 3D Model

The scan is imported into Zeiss software, then into GeoMagic, where the real labor begins.

Andy is blunt about this step:
“That’s where the real challenging work is.”

GeoMagic technicians must:

• Remove noise and dust

• Patch pores

• Stitch fractured meshes

• Shape it into a usable solid

Only after this cleanup does the model enter SolidWorks, where it “can be actually used as a 3D model and measured… and then it goes into computer programming for the CNC machines.”

This is why the reengineering process for parts isn’t just “scan it and make it.” As Andy says:

“You realize the scan takes half an hour to an hour, and then you have six hours of work to actually put it onto a machine.”

Step 3: CNC Machining the Part

Once modeled, the part moves to production. This is where Truco’s machining experience shines. Because the digital model is precise, CNC can replicate even small details, including flaws the scanner caught, such as “holes that are not on center.”

This accuracy is critical for pharmaceutical, food, and high-reliability environments.

Step 4: Inspecting the Finished Part

One overlooked benefit of the reengineering process for parts is the ability to re-scan the finished part and compare it to the original.

Andy highlights this:
“You can scan it and inspect it… It’ll show you where the differences are… It will tell you if you have a good part or not.”

Not every shop offers this level of verification.

Why Repeatability Matters

Truco focuses on repeat-order components, what Andy calls “your sacrificial gear” situations.

“We’re not looking for onesie-twosies,” he says. “We’re looking for repeats.”

Scanning once means you can reorder quickly… and Truco can build inventory for you.

This makes the reengineering process for parts an investment, not a one-off purchase.

Is Reengineering Right for You?

Reengineering is ideal when:

• OEM parts are expensive or discontinued

• You replace the part regularly

• Downtime is costly

• You want domestic availability

• You have no engineering print

It’s NOT ideal when the part is cheap to buy new.

If you’re unsure, Andy’s advice is simple: Start with the replacement cost first.

Ready to Start the Reengineering Process for Parts?

If you’re dealing with a worn, broken, or impossible-to-find part, Truco can help you recreate it with accuracy and reliability.

Upload a photo. Share the material, function, quantity, and replacement cost. Then let the experts take it from there.

“No print? No problem.”