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Reverse engineering and robotic blending
We scan the part, rebuild its geometry in CAD and turn it into robot paths. Every blade or vane is blended to its own best-fit form, with repeatable results and data you can use again.
From physical part to precise repair, in six stages
The same workflow for OEM and MRO parts. Below, step through how we design the robotic cell itself.
- 01
Share the part
Send the part, or photos of it, and mark the area to blend or repair.
OEM or MRO parts - 02
Set the reference
One best part for OEM work, a best-fit form for each MRO part. We agree the final precision with you.
Precision agreed - 03
Scan and index
A blue-light scanner measures the part on a calibrated turntable, located by an indexing point.
Within 100 µm - 04
Scan to CAD
Scan data becomes a CAD model with a best-fit contour, checked against the reference.
Best fit, part by part - 05
Design the cell
Payload, collaborative robot, axes of movement and tool reach are designed and simulated before anything is built.
Simulated before build - 06
Blend and check
The robot blends to the CAD form with compensation applied, and dimensions are held to the agreed tolerance.
Same result, every part
How we design a blending cell
Step through our design process. Each step lights up the part of the cell it decides.
What reverse engineering gives a repair shop
New turbine parts keep getting more expensive, and nickel and cobalt alloys are scarce. Engines run hot in a corrosive environment, so parts come back distorted and dirty, and repair yield matters more than ever. We bring precision to the repair process with the right inputs and custom tools.
- Find the precise reason for the repair before choosing a method
- Precise scanning of each part
- Best-fit contours, so repairs keep as much base metal as possible
- Robots that repeat the same blend on every part
- Software that converts scan data to CAD and CAM
- CAM data reused for other repair steps
- Inspection methods that decide whether a part is repairable
- Process data you can use for future ML and AI
We build repair process developments, not just repairs.
Equipment and precision
- Turntable
- Precision, programmable movement from the central controller, in very fine steps.
- Scanner
- Blue-light or specialised industrial scanner measuring within 100 microns. Finer precision is possible if needed.
- Fixture
- Precision part holder designed around the degrees of freedom of the scanner and the part, with access to every area of interest.
- Indexing tools
- Calibrated tools that locate the part in space so its dimensions can be measured as needed.
- Robot
- Collaborative robot as the central unit, selected to work with every tool safely and deliver the result.
- Blending tool
- Strong enough to remove material, light enough for the robot payload. Roll or polishing blender.
- Blending belts
- Chosen for the surface finish you need and the metallurgy of the part.
- Control unit
- PLC and HMI. Inputs from every tool are turned into clear, interactive screens for the operator.
- Tool holders
- Designed in-house to carry the tools above, with dimensional tolerancing checked throughout.
Ergonomics and the operator come first: the systems we design are easy to run.
Parts and areas we blend
- Turbine blades
- Tip area, platform, near the trailing edge on the suction side, near the leading edge on the pressure side. Including tip-welded blades.
- Turbine vanes
- Platform areas, pressure and suction sides, inner and outer platforms.
- OEM or MRO
- Cast or forged OEM surfaces to finish, or service-worn MRO parts to restore.
What we need to quote a system
- The actual part, or pictures of it
- A clear description of the area of interest
- Any processing before blending
- The surface finish you expect
- Finished dimensions, as a CAD file or a master part
- Your timeline
- The productivity you expect
- The precision you expect
Frequently asked questions
Not covered here? Call +65 9060 0775 or send us the details.
How precise is the scanning?
Blue-light or industrial scanners measure within 100 microns, and finer precision is possible where the part needs it.
Do you work with OEM and MRO parts?
Yes. For OEM parts we follow a single best part. For MRO parts we build a best-fit form for each part, so we remove no more metal than needed.
Do you design the whole cell?
Yes. We design the cell around your part and select the equipment: robot, turntable, fixtures, indexing tools, scanner, blending tools and the PLC and HMI control.
What do you need from us to quote?
The part or pictures of it, the area of interest, any processing before blending, the finish and final dimensions you need (as CAD or a master part), your timeline, productivity and precision.
Send us the part and the area to blend. We will design the cell.
Call +65 9060 0775 or email metcondndt@gmail.com