The machine is down and the manufacturer no longer supplies the part. Often, custom spare part manufacturing is the only way out.
As a precision engineering and CNC manufacturer in Werl, Vulcanus makes spare parts from samples, sketches or CAD data.
This guide shows what documents you need, how the process works and what drives cost and lead time.
Key Takeaways
- Spare parts can be remanufactured from a drawing, CAD data, sketch or sample.
- The more complete the documents, the faster and cheaper the job.
- Without a drawing, the part is measured and digitally reconstructed.
- For loaded metal parts, CNC machining is usually the best route.
- Remanufacturing is a chance to improve material and design.
When Should You Have Spare Parts Remanufactured?
Typical Situations
- The original manufacturer no longer exists or no longer supplies the part
- The original part’s lead time is far too long
- The original part’s price is out of proportion
- The part wears too quickly and should be improved
- A machine is being modernised and needs adapted parts
Many of these cases share a structural cause. Our article on spare parts obsolescence shows how to manage it long term.
The Cost of Waiting
Every day of downtime costs output, labour and often customer trust. Production downtime quickly exceeds the price of the spare part. Fast remanufacturing is therefore often the cheapest option.
Typical Metal Spare Parts
- Shafts, axles and rotor shafts
- Gears, pinions and coupling parts
- Bushings, flanges and bearing housings
- Wear strips, knives and crushing tools
- Rollers, guides and conveyor parts
Conveyor systems in particular contain many such wear parts. Our article on conveyor system components gives examples.
What Documents Do You Need?
The starting point determines effort, price and lead time. There are four routes.
Technical Drawing
A complete drawing with dimensions, tolerances and material is the best basis. The manufacturer can quote and programme directly. This saves time and reduces risk.
CAD Data
3D models speed up programming considerably. Tolerances, surfaces and material still need to be specified. A model alone does not show which dimensions are critical.
Dimensioned Sketch
A hand sketch is often enough for simple parts. The manufacturer turns it into a production drawing. Mark critical dimensions clearly.
Sample or Old Part
If only the original part is available, it is measured and reconstructed. Worn or broken parts also work as samples. The manufacturer then determines the original nominal dimensions.
Information That Always Helps
- Installation situation and function of the part
- Known or suspected material
- Loads such as force, temperature or wear
- Required quantity and target delivery date
- Photos of the part as installed
Shipping a Sample Correctly
Clean the part roughly, but do not remove wear marks. They show where the part is loaded. Include photos of the installation and a short description.
Custom Spare Part Manufacturing: The Process in Six Steps
1. Enquiry and Initial Review
You send a drawing, sketch, photos or the sample. The manufacturer checks feasibility, material and effort. This leads to an initial quote.
2. Measurement
If documents are missing, the sample is measured. Tactile measuring arms capture geometry and fits very accurately. Our article on precision measurement covers methods and accuracy.
Measuring Parts in Place
Some parts cannot be removed without long downtime. Portable measuring arms then capture them directly on site. Mating parts and interface dimensions are recorded at the same time.
3. Reconstruction and Drawing
The measurement data becomes a 3D model with a production drawing. Wear is compensated to restore the original geometry. Our article on reverse engineering components describes the process.
The new drawing has value in itself. Next time, you can reorder directly.
4. Material Identification
If the material is unknown, testing such as spectral analysis helps. Often, the material can also be inferred from application and hardness. Our guide to CNC material selection explains the basics.
5. Manufacturing
The part is turned, milled, sawn or welded. Where needed, heat treatment and surface protection follow. Functional surfaces are finished to the required manufacturing tolerance.
6. Inspection and Documentation
Critical dimensions are measured before delivery. A measurement report documents quality. Drawing and inspection data remain available for future reorders.
Which Manufacturing Process Fits?
CNC Machining
For loaded metal parts, CNC machining is the standard. It achieves tight tolerances and handles almost all steels and special materials. Single parts are economical too, as our article on low volume manufacturing shows.
3D Printing
3D printing suits plastic parts, complex geometries and prototypes. For heavily loaded metal parts, it is often too expensive or not strong enough. Our comparison of additive vs subtractive manufacturing weighs both.
Large and Heavy Parts
Shafts, rotors or housings weighing several tonnes have special requirements. They need large machines, crane capacity and experience. Our article on CNC machining for large parts explains what matters.
Casting and Welded Fabrication
Large castings can often be replaced by welded fabrications. This saves pattern costs and lead time. Functional surfaces are then machined.
The original process does not decide; the part’s function does. A former casting is often better milled or welded.
Repair Instead of Remake
Not every worn part needs to be made from scratch. Often, bearing seats can be built up by welding and remachined, or bushings fitted. Our overview of welding processes shows the options.
Remanufacturing as a Chance to Improve
Upgrade the Material
If a part wears too fast, a harder or tougher material can help. Targeted hardening of functional surfaces also extends service life. The spare part becomes a better part.
Adapt the Design
Weak points such as sharp edges or thin sections can be fixed during remanufacture. Installation dimensions and interfaces must stay unchanged. Always agree changes with maintenance.
Protect the Surfaces
Coatings and surface treatments protect against corrosion and abrasion. Our article on surface treatments gives an overview.
Cost and Lead Time
What Drives the Price
- Quality of documents: drawing, sketch or only a sample
- Size, geometry and tolerances of the part
- Material and its availability
- Extra steps such as hardening, grinding or coating
- Quantity: follow-on parts cost much less than the first
Our guide on how CNC quotes are calculated shows how these factors shape a quote.
Shortening Lead Time
- Send complete documents and photos with the enquiry
- Clearly identify functionally critical dimensions and tolerances
- Choose common materials where the function allows
- Make the sample available for measurement quickly
One Part or Several?
A second part for stock usually costs a fraction of the first. Setup and programming are already done. For critical wear parts, a small reserve pays off.
Making Reorders Easy
Archive the drawing, material and inspection report for every remanufactured part. Assign your own part number and record the supplier. This noticeably lowers maintenance costs at the next failure.
Framework Agreements for Wear Parts
If the same parts are needed regularly, a standing agreement pays off. The manufacturer keeps programmes and material ready. In an emergency, this shortens lead time considerably.
Legal Notes
Remanufacturing for your own use is generally unproblematic. For patented or protected components, however, intellectual property rights may apply. If in doubt, check the legal position before production.
Safety-critical parts require particular care. Material and dimensional accuracy must at least match the original.
Finding the Right Partner
Not every shop is suited to spare parts. Look for these points:
- Experience with single parts and remanufacturing without drawings
- In-house metrology for measurement and final inspection
- Machines for the size and material of your part
- Fast response times and direct technical contacts
Our article on how to choose a CNC machining supplier covers further criteria.
Custom Spare Part Manufacturing at Vulcanus
Vulcanus-Stahl & Maschinenbau in Werl makes spare parts from samples, sketches or CAD data. We machine parts that other shops turn down because of size or material.
- Examples: rotor shafts, discs for rail vehicles, wear plates for presses and cable press components
- Metrology: tactile FARO measurement, also directly on installed components
- Reverse engineering: 3D modelling and production drawings from the sample
- Manufacturing: milling up to 10 tonnes, turning up to 1,200 mm diameter, hard sawing up to 65 HRC
- Welding: certified to DIN EN 1090-2 EXC3 and DIN EN ISO 3834-2
Learn more about repair, spare parts and metrology on our precision manufacturing page. For background on machine parts supply, see our article on CNC spare parts.
Custom Spare Part Manufacturing Keeps Your Machines Running
A missing spare part does not have to mean the end of a machine. With a drawing, a sketch or just the old part, almost any metal part can be remanufactured.
The better the documents, the faster the solution. Often, the result is a part that lasts longer than the original.
Machine down and the spare part unavailable? Contact Vulcanus with a photo, sketch or drawing for a quick assessment.
FAQ: Custom Spare Part Manufacturing
Can spare parts be made without a drawing?
Yes. The old part is measured, digitally reconstructed and turned into a production drawing. This works for worn parts too.
What documents should I send?
Ideally a drawing or CAD data. Otherwise, a sketch, photos, a description of the function and the sample itself help.
How long does remanufacturing take?
It depends on documents, size and material. Simple parts with a drawing are often ready in a few days.
Is a remanufactured part as good as the original?
When made properly, yes. It can often be improved with a better material or targeted hardening.
Is it worth remanufacturing a single part?
Usually yes, especially compared with downtime costs. A second part for stock is also much cheaper than the first.
Is it legal to copy spare parts?
For your own use, generally yes. For protected components, check possible intellectual property rights first.