An Integrated Approach to Reconstructing a Damaged Plastic Component Using Reverse Engineering and Additive Manufacturing

This work presents a case study detailing an end-to-end workflow for reconstructing a damaged plastic component when no original design data are available. The approach integrates microscopic inspection of fracture surfaces, selective enhancement of 3D scan data, CAD-based modification of geometrically and functionally critical features, and continuous fibre-reinforced additive manufacturing. The component examined functions as a structural mounting element in an automotive lighting module, where it maintains correct alignment and provides mechanical support in service. The study concentrates on the cost-effective replacement of unique parts produced in very small batches. The results indicate that this fracture-analysis-informed reverse engineering strategy offers a practical solution for reproducing low-volume, custom, or replacement components in situations where standard manufacturing methods are not economically viable. The reconstructed part matched the geometry necessary for installation in the original assembly and successfully passed initial functional checks; however, this study did not include quantitative measurements of mechanical performance.