{"id":4187,"date":"2026-05-28T12:43:29","date_gmt":"2026-05-28T12:43:29","guid":{"rendered":"https:\/\/tetravision.be\/case\/een-gebarsten-zwembadcomponent-digitaal-heropgebouwd\/"},"modified":"2026-05-28T12:58:08","modified_gmt":"2026-05-28T12:58:08","slug":"a-cracked-swimming-pool-component-digitally-reconstructed","status":"publish","type":"case","link":"https:\/\/tetravision.be\/en\/case\/a-cracked-swimming-pool-component-digitally-reconstructed\/","title":{"rendered":"A cracked swimming pool component digitally reconstructed"},"content":{"rendered":"\n

CT scanning and reverse engineering of a replacement part for Machinified BV<\/h2>\n\n\n\n

When a part breaks and the original is no longer available, reverse engineering offers a solution. For Machinified BV<\/a> in Leuven, we converted a cracked plastic swimming pool component into a complete CAD model. Using our ZEISS Metrotom 6 Scout and QuickSurface\u2019s reverse engineering software, we reconstructed the entire geometry, including the threads, so that the part could be reproduced via 3D printing.<\/p>\n\n\n\n

Project at a glance<\/h2>\n\n\n\n
Customer<\/strong><\/td>Machinified BV<\/a> (Leuven, BE)<\/td><\/tr>
Application<\/strong><\/td>Reverse engineering of a cracked plastic swimming pool component for reproduction<\/td><\/tr>
Component<\/strong><\/td>Plastic cover component with fine internal threads<\/td><\/tr>
Challenge<\/strong><\/td>Part has cracked and is no longer available; no original CAD data is available; the thread is critical for a proper fit in the existing pool installation<\/td><\/tr>
Scanning Technology<\/strong><\/td>X-ray CT scanning (ZEISS Metrotom 6 Scout<\/a>)<\/td><\/tr>
Reverse engineering<\/strong><\/td>QuickSurface<\/a><\/td><\/tr>
Validation<\/strong><\/td>ZEISS Inspect, with color plot scan vs. CAD<\/td><\/tr>
Output<\/strong><\/td>Complete CAD model in STEP format, including a validation report in PDF<\/td><\/tr>
Reproduced by the customer<\/strong><\/td>SLS 3D print in PA12<\/td><\/tr>
Lead time<\/strong><\/td>About two days<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

The customer’s request<\/h2>\n\n\n\n

Machinified BV from Leuven approached us with a seemingly simple problem: a cracked plastic component from a swimming pool system for which no replacement was available. The part had to be remanufactured, which first required creating a precise CAD model of the existing component.<\/p>\n\n\n\n

The challenge lies in the internal geometry: the component features a detailed thread that must fit exactly into the existing swimming pool setup. There is no margin for error with that thread. If the thread doesn\u2019t fit, the entire part won\u2019t fit, and the whole process will have been for nothing.<\/p>\n\n\n\n

On top of that, the physical condition of the original was a concern. The part showed a clear crack, as well as localized wear and deformation. The CAD model therefore had to do more than simply copy the scan; it had to reconstruct the original geometry as the part was originally designed, without incorporating the damage.<\/p>\n\n\n\n

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Our approach<\/h2>\n\n\n\n

For this project, we opted for a combination of X-ray CT scanning and reverse engineering using QuickSurface. CT scanning was the obvious choice here: the part features internal geometry and a thread that are either impossible or much more difficult to capture accurately using optical 3D scanning. With CT scanning, we obtain 100% of the data, both internal and external, in a single run and without causing any damage.<\/p>\n\n\n\n

Step 1: X-ray CT scanning with the ZEISS Metrotom 6 Scout<\/h3>\n\n\n\n

The ZEISS Metrotom 6 Scout<\/a> is ideally suited for plastic components such as this one. By combining a 3k detector with a 225 kV X-ray source, we achieved the resolution and contrast needed to capture all details, including the fine screw threads, with sharp clarity. The result is a high-resolution mesh that accurately represents the part\u2019s entire internal and external geometry.<\/p>\n\n\n\n

The advantage of CT scanning is that it visualizes areas that are difficult or impossible to access with traditional measuring equipment. For this component, that was not a luxury but a necessity: without the internal data, a correct thread reconstruction simply would not have been possible.<\/p>\n\n\n\n

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Step 2: Reverse engineering with QuickSurface<\/h3>\n\n\n\n

Using the scan data as a starting point, we then got to work in QuickSurface<\/a>. This software was the logical choice for this project: it allows us to quickly build a clean, production-ready solid body from a mesh, with specific functionality for revolved geometry and thread reconstruction.<\/p>\n\n\n\n

QuickSurface itself detailed the entire workflow for this project in a comprehensive video, using our scan data as the starting point. The video shows, step by step, how to go from a scanned, cracked plastic component to a fully reusable CAD model. For anyone considering a similar process, this is one of the most comprehensive online demonstrations of an end-to-end scan-to-CAD workflow on a real part.<\/p>\n\n\n\n

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