A typical situation: the equipment runs, a part wears out, the manufacturer has left the market, and there are no drawings. Reverse engineering solves this systematically — design documentation is restored from a physical sample, and the part becomes reproducible at a Russian site.
Step 1. Measurement and geometry restoration
The sample is measured — from calipers and micrometers for simple rotational parts to CMM and 3D scanning for complex surfaces. A worn part cannot simply be “copied”: the engineer restores the nominal geometry, separating wear from design dimensions, and checks the fits against the mating parts.
Step 2. Material and heat treatment
The material grade is identified by spectral analysis, hardness by HRC/HB measurement. Then a Russian analogue is selected — for example, 40KhN2MA or 40Kh instead of European 42CrMo4, with adjusted heat treatment. This is where service life is often improved: raise surface hardness or change the friction pair.
Step 3. Design documentation and process
Working design documentation is developed — tolerances, surface finish, heat treatment and coating requirements. In parallel, a production process is written for the specific site: operation sequence, tooling, control points.
Step 4. Pilot batch and testing
The first batch is a pilot. The part goes into the unit, runs a control interval, and remarks are resolved. For critical items, independent laboratory tests confirm mechanics, chemistry and coating durability. Only then does the series start.
What the customer gets
A documentation package (it stays with the customer), a reproducible part at a Russian site, a safety stock and deliveries to the maintenance schedule. In FLOK’s experience, a localized part comes out 1.5–3 times cheaper than the imported analogue, and sample-to-series takes six weeks to five months depending on complexity.
Send a sample or a photo of the part — the FLOK engineering team will assess documentation restoration and return with a localization plan.