Reverse Engineering

Reliable Replication. Material Identification. Consistent Performance.

What is it?

Reverse engineering is the process of taking an existing part and recreating it when drawings, specifications, or material details are unavailable.

In engineering plastics, this involves analysing the original component, identifying the correct material, and establishing a manufacturing method to reproduce it accurately.

This is a practical solution for worn, obsolete, or custom parts where replacement options are limited or unavailable.

Our Reverse Engineering Process

1. Component Assessment

We start by examining the existing part to understand its function, load requirements, wear patterns, and environment. This helps determine what matters most — strength, wear resistance, chemical stability, or dimensional accuracy.

2. Material Identification

Selecting the right material is critical. We assess the original component and match it with suitable engineering plastics such as:

HDPE (High Density Polyethylene)
Nylon (PA)
Acetal (POM)
UHMWPE
PTFE (Teflon)

Material selection is based on performance, not guesswork, ensuring the new part meets or exceeds the original.

3. Measurement & Documentation

Accurate measurement is taken from the sample part using precision tools. Where required, tolerances are refined to improve fit and performance.

4. Process Selection

We determine the most suitable method to recreate the part:

CNC machining from engineering plastic rod or sheet
Processing and assembly
Modification of existing components

This ensures efficiency, repeatability, and cost control.

5. Prototyping & Testing

If needed, we produce a prototype for testing before full production. This step reduces risk and confirms performance in real conditions.

6. Production & Supply

Once approved, parts are manufactured and supplied with consistency for ongoing use or repeat orders.

30+ Years of Experience You Can Rely On

With over 30 years of hands-on experience, we bring practical knowledge of engineering plastics, machining, and real-world applications. This experience allows us to quickly identify materials, troubleshoot design issues, and deliver parts that work the first time.

Why Reverse Engineer?

Replace obsolete or discontinued parts
Improve performance over original materials
Reduce downtime in machinery or equipment
Avoid costly redesigns
Enable local Australian supply and fast turnaround

Common Applications for

Reverse Engineered Plastic Parts

Industrial machinery components

Wear strips, guides, and rollers

Bushings and bearings

Food processing equipment

Automotive and transport applications

Mining and agricultural equipment

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Why Choose BB Engineering Plastics?

Australian owned small family business
Practical, experience-based solutions
Wide range of engineering and industrial plastics in stock
Quality CNC Cutting & Machining
Fast turnaround times

Request a quote

Ready to get started?

If you have a worn, broken, or hard-to-source plastic component, we can help. Provide a sample or photos, and we’ll guide you through the reverse engineering process.

Request a quote