Replicating Vintage Detail – Only Better

The challenge

The client was restoring a historic Soviet go-kart. It had to race, not just look good. The problem – the frame was there but some of the crucial details were missing. So we had to reverse engineer a high durability detail without applying our 3D scanning capabilities

Relying only on old photos, we are able to build a rough CAD model in Autodesk Alias.

The process

Relying only on old photos, we are able to build a rough CAD model in Autodesk Alias. For the programming of our continuous 5-axis CNC mill Hermle C32, we are using our preferred HyperMILL CAM package. It made us a functional model that could also be mirrored in production – something that proved useful later on. The next step was to make it look true to the period. Our product designer treated the model stylistically, rounding up the edges and giving it a recognisable 1980s look.

Production

Our 5-axis CNC milling machine Hermle C32 is capable of producing the detail in one go, saving on re-fastening. It autonomously replaces details on the mill, making it possible to manufacture single units in between mass production runs without human intervention. The milled pedal was easy to break by hand from the block, so small was the touchpoint. Coming out from the machine, it already has top of the line surface quality – which means that it does not need any additional treatments such as polishing or sanding.  The pedal is good for racing, its durability significantly exceeding that of the original detail. Mission accomplished!

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