Obsolete and discontinued part replacement
Lycan Core develops replacement parts from broken originals, photographs or existing samples. Drawings and CAD files are not required to begin. The replacement is measured, modelled, test fitted where necessary and manufactured in a material selected for its actual operating conditions.
Suitable applications
- Machine components that are no longer supported by the original manufacturer.
- Imported parts with lead times that make continued downtime impractical.
- Low-volume brackets, housings, covers, guards, clips, knobs, ducts, spacers, guides and mounts.
- Automotive and motorsport parts that are unavailable or need to fit a modified vehicle.
- Legacy equipment for which the physical part is the only remaining reference.
Once the replacement has been modelled and proven, further units can be produced without repeating the full measurement process.
From original part to replacement
- Send the available informationPhotograph the part next to a ruler and include the main dimensions, its application and the quantity required. If it has broken, photographs of both sides and the fracture area help identify how it was loaded.
- Receive an initial assessmentWithin 24 hours, Lycan Core will confirm whether additive manufacture appears suitable, what further information is needed and which material family should be considered.
- Measure the originalParts in Gauteng can be scanned and measured on site at no charge. Projects elsewhere in South Africa can often begin from photographs, dimensions and a couriered sample.
- Model and test the fitThe replacement is modelled in SolidWorks, Inventor or Fusion 360. A PLA test piece is used where interfaces or mounting points need to be checked before final manufacture.
- Manufacture in the selected materialThe final material is selected around loading, temperature, sunlight, moisture, chemicals and the failure mode of the original part. Completed parts can be sent throughout South Africa.
Material selection
Material selection starts with the application rather than the printer. Load, temperature, weather exposure, chemicals, required stiffness and the original failure mode are reviewed before a recommendation is made. The material and the reason for selecting it are recorded in the quotation.
| Material | Typical use | Important consideration |
|---|---|---|
| PA12-CF | Stiff brackets, housings and structural components | Requires controlled drying and abrasion-resistant printer hardware |
| PA12 | Tough parts, guides, bushes and components exposed to wear | Moisture condition must be controlled during printing |
| ASA | Outdoor covers, ducts and housings | Selected where UV and weather resistance are important |
| ABS | Parts that will be bonded, sanded or painted | Printed in an enclosed machine |
| PET-G | General parts exposed to water or occasional splashes | Chemical compatibility is checked for the specific application |
| PLA | Fit checks and geometry prototypes | Not used for hot or long-term load-bearing applications |
Pricing and turnaround
The written assessment, on-site measurement and CAD modelling are free. Further detail is available on the on-site scanning and measurement page. The manufactured part is quoted once the geometry, material and quantity are understood.
Designed replacements typically take 1–2 weeks. Printing from an existing, production-ready file typically takes 3–5 working days. The confirmed lead time is stated in the quotation because part size, material and test-fit requirements can change the schedule.
When another manufacturing route is more appropriate
- Production quantities in the thousands are normally better suited to injection moulding.
- Certified or safety-critical load-bearing parts require the appropriate analysis and formal sign-off.
- Parts exposed to conditions beyond the available material data should not be produced without testing.
Completed examples
Current examples include a motorsport badge developed from a photograph and wheel-arch louvres measured on the vehicle. Each project is documented with the process, material and development problems in the job record.
Send photographs of the unavailable part
Include a ruler or known dimension in the photographs, together with where the part is used and how the original failed. A written assessment will follow within 24 hours. If the part has broken, include photographs of both pieces and the fracture area.
Send photographs by email →bismarcklouw@gmail.com · Enquiries answered within 24 hours