Case Study: How We Reverse Engineered a Casting into a Custom Manifold

Blue STL model created by 3D scanning the engine manifold casting.

Grey surface model (NURBS) of the engine manifold casting created from the STL model.

Grey model of the engine manifold with yellow highlights on the machined surfaces.

STL mesh model of the cast engine manifold

NURBS surface model of the casting

Parametric model of machined engine manifold

The problem

Our customer, a prominent player in the automotive aftermarket industry, approached us with a specific challenge: they needed a reverse engineering solution for creating a custom machined Subaru Impreza High Volume Inlet Manifold from a Cosworth Intake Manifold Casting. The project involved detailed communication and coordination between our team, the customer, and a third-party machine shop.

The solution

To deliver the desired outcome, we utilised our range of scanning technology including 3D laser scanning and high-accuracy CMM inspection, together with our 3D CAD modelling software. We began by using our 3D laser scanning to capture highly accurate data on both the Cosworth casting and on an existing machined Impreza manifold. By creating CAD models for both and aligning these to each other using common features, we were then able to update the Cosworth model to incorporate the machined features from the Impreza model. Next, we updated the model’s tight tolerance features based on results obtained from our high accuracy CMM. Finally, we generated detailed 2D engineering drawings outlining the machining requirements for the new custom inlet manifold.

The result

Thanks to our comprehensive approach and the use of advanced technology, we were able to successfully deliver the project on time and to the satisfaction of our customer. The newly machined Subaru Impreza High Volume Inlet Manifold has been put to the test on the track and has performed flawlessly, exceeding our customer’s expectations.

The conclusion

This project serves as a testament to our expertise in the 3D scanning and reverse engineering industry and our ability to deliver custom solutions that meet our customers’ specific needs. By leveraging a range of cutting-edge technologies and collaborating closely with our customers and partners, we were able to achieve a successful outcome that has since delivered measurable value to our customer’s business.

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About Us

AB Technology started out as an independent CMM Inspection & Programming company based near Nottingham, UK. Over the last 25+ years, we have expanded our services to include 3D scanning and reverse engineering, serving customers of all sizes, across an array of industry sectors, both domestically and internationally.