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Industrial & Manufacturing
Industrial Milling Equipment Rebuild
CLIENT / TARGETHeavy Manufacturing Facility
INDUSTRYIndustrial & Manufacturing
LOCATIONSoutheastern United States
APPLIED VERMATI ARCHITECTURE LAYERS
✓ DESIGN
✓ BUILD
OPERATE
✓ VERIFY
Core Technical Requirement
Reverse engineer and manufacture replacement drive shafts, gear housings, and custom bearing blocks for a critical milling line where original OEM drawings were unavailable.
Engineering & Operational Constraints
- •Zero original CAD files or engineering prints in existence
- •High dynamic loads requiring heat-treated 4340 alloy steel precision machining
- •Unplanned shutdown incurring significant downtime cost per day
Vermati Scope
- On-site 3D Laser Scanning & Physical Component Teardown
- Parametric Re-engineering & FEA Stress Analysis
- CNC 5-Axis Turning & Precision Machining
- Quality Assurance Inspection & Hardness Testing
Execution Approach
- STEP 01Deployed technical team for 3D laser scan of worn mating components on-site.
- STEP 02Rebuilt parametric 3D CAD models accounting for wear patterns to restore original nominal dimensions.
- STEP 03Performed FEA load simulations to optimize shaft fillets and eliminate stress concentrations.
- STEP 04Dispatched manufacturing to precision machining network partner with heat-treatment & ground finishing.
Deliverables
✓ Fully Documented Parametric 3D CAD Solid Models & 2D Manufacturing Drawings
✓ Hardened 4340 Steel Main Drive Shaft Assemblies
✓ Precision Machined Bearing Blocks
✓ Hardness Test Certificates & CMM Dimensional Audit Reports
Work Material
Representative Material
3D Laser Scan vs CAD Surface Deviation Map
Color-coded 3D deviation map highlighting original component wear vs reconstructed CAD geometry.
Representative Material
Final CMM Inspection Report
Co-ordinate Measuring Machine audit verifying bearing journal diameters and runout.
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