Flash on a stator component: identifying and permanently eliminating the cause
Remanufacturing a tool insert using 3D laser scanning and reverse engineering
When flash keeps recurring in production and reliable CAD documentation is unavailable, immediate stopgap repairs are not the answer.
The first step is to reconstruct the geometry – only then can a sound engineering decision be made.
Customer
Precision manufacturing company with a multinational background
Component
Injection-moulded stator with an iron core
Objective
Eliminate flash,
stable production
Technology
3D laser scanning and reverse engineering
The challenge: flash on the component and unstable production
Our partner approached us because flash had appeared on an injection-moulded stator component. After checking the production parameters, it became clear that the defect was caused by a worn tool insert rather than process settings.
- Quality complaints and scrap
- Costly rework in series production
- Delivery deadlines at risk
The engineering decision: remanufacture rather than repair
After examining the insert's condition in detail, we had two options.
Our aim was a long-term solution.
Welding and remachining
- Time-consuming due to the extent of surface wear
- Difficult to carry out because of the complexity of the affected surfaces
- A more expensive solution for the above reasons
Recommended solution
Complete remanufacture
- Stable geometry for flash-free shut-off
- 3D laser-scanned precision
- Permanently available digital model
3D laser scanning: capturing the actual geometry
We digitised the worn insert using an industrial 3D laser scanner.
This step provided the basis for engineering certainty.
- High-precision capture
- Visual identification of worn surfaces
- A reliable digital basis for manufacturing
Digital reverse engineering: reconstructing the missing geometry
Our engineers created reference geometry from sections in good condition, then reconstructed the complete model using a symmetrical arrangement.
The result:
a perfect, manufacturable 3D model.
Wire EDM correction for a perfect fit
The new insert was manufactured from the reconstructed model, but trial production showed that the fit of the stator's iron core required further fine-tuning.
- Modification of critical surfaces
- Application of precise offsets
- Precision wire EDM rework
Production flexibility: zero downtime
We removed the tool insert only for the short scanning period, allowing the customer's production to continue throughout the process.
Fast scanning
Uninterrupted series production
Remanufacture
Results
Whether you face worn tool inserts, missing 3D documentation or recurring quality defects, our engineering team is ready to provide a solution.
Don't wait for scrap rates to rise – ask our experts to help restore your process!
