Case studies
Engineering in practice
Design engineeringPrototypeProduction
Classic car supercharger manifold
The challenge
A small business producing supercharger kits approached Agile3D to reduce the cutting, welding and finishing required for each manifold.
What we did
We reviewed manufacturing options and redesigned the fabricated assembly for gravity casting, improving packaging clearances and airflow geometry. Scanning, CAD and 3D printing supported checks of airflow performance, fit and assembly before investment in tooling.
Working directly with the casting supplier, we refined the design for cost and manufacture, then supplied detailed CAD and BS 8888 technical drawings.
The outcome
The client went on to scale production, freeing up time to grow the business and develop further products with Agile3D.
Services
Engineering detail
Scanning, CAD and printed prototypes supported fit, assembly and airflow checks before investment in casting tooling.
Design engineering
Supercharger to carburettor adapter
The challenge
Agile3D took a client’s mock-up of a supercharger-to-carburettor adapter and developed it into a detailed CAD model using 3D scanning and reverse engineering.
What we did
The scanned geometry provided a reference for rebuilding the component, refining its surfaces and features for CNC machining. The design was subsequently developed for casting, supporting the transition to a different production process.
The outcome
The project took an existing physical concept through digital reconstruction to a manufacturable component, with the design adapted to suit each manufacturing route.
Services
Engineering detail
The scan served as a reference for rebuilding the geometry. Surfaces and features were refined for CNC machining, and the design was later adapted for casting.
Design engineeringPrototype
Ophthalmic lens quick testing device
The challenge
Agile3D developed a contact lens testing device around the requirements of a contact lens optician. Components were optimised for 3D printing, with future injection moulding considered throughout the design.
What we did
We advised on manufacturing costs and benefits, selecting FDM for the main handle and SLS for the turning components. Polycarbonate was identified for further assessment against the intended medical application’s requirements. We also designed and applied custom scale stickers to finish the printed units.
The outcome
The printed units combined the handle, rotating holders and custom scale stickers in a complete device. Detailed CAD models and 2D drawings gave the client the information needed to explore production routes and discuss manufacture with potential suppliers.
Services
Engineering detail
The printed units were developed with a later move to injection moulding in mind, so the design considered both the immediate build and a future production route.
Design engineeringProduction
Bespoke windscreen gap setters
The challenge
A windscreen fitting company approached Agile3D for bespoke gap setters sized to suit its installation requirements, with material selection addressing exposure to the chemicals and adhesives used during fitting.
What we did
We designed the components around the required gap sizes, bringing them together in a compact folding assembly with individual size markings for easy identification.
The outcome
We manufactured or sourced the fasteners and delivered the bespoke tools fully assembled and ready for use, with individual size markings for easy identification.
Services
Engineering detail
Material selection needed to account for exposure to the chemicals and adhesives used during windscreen fitting, alongside the tool’s required gap sizes and folding arrangement.
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