Restoring a Camper Awning Gearbox with Custom 3D-Printed Components

Solving The Awning Gear Challenge

When a local client approached us with a completely stripped gear from their camper awning, we saw an opportunity to demonstrate the value of precision reverse engineering and advanced manufacturing techniques. This project not only restored the awning gearbox to full functionality but also saved the client from a costly replacement, showcasing the power of modern engineering solutions.

How damaged was the Awning Gear?

The client, from the Whakatane area, encountered a problem when their camper awning lock wasn’t disengaged before operation. Turning the handle caused the internal injection-molded plastic gear to strip under the stress. With the original gear beyond repair, the client needed a replacement to restore the gearbox and avoid replacing the entire awning system, a solution that would have been expensive and time-consuming.

After finding us via a Google search, the client contacted us with photos of the damaged gear. Confident in our ability to help, we requested the gearbox components for a closer inspection. The goal was clear: reverse-engineer the damaged part and provide a cost-effective, reliable replacement.

Gear Re-Creation

• 3D Scanning: Using the Creaform HandyScan 700, we 3D-scanned the damaged gear. This ensured every detail was captured for the design phase.

• CAD Modeling: We generated a CAD model in Autodesk Inventor 2025, recreating the gear’s tooth pitch. To optimize production, we decided to print the gear in two halves horizontally positioned on the print bed, a method that improved both print quality and structural strength.

• Material Selection: PETG, a robust and durable material, was chosen for its suitability in low-load applications like the awning gearbox. While not as hard as the original material, PETG offered an ideal balance of strength and flexibility for the operating conditions.

• Manufacturing: The gear was printed with 100% infill for maximum solidity. We incorporated a new tension pin hole to ensure secure fitment and precise alignment during the gear fitment process.

• Drilling: Once printed, the gears were first aligned and bonded together using Henkel Loctite HY 4070 structural adhesive, the assembled gear was then set up on a drill press to create a new tension pin hole, the stainless steel shaft had undergone various rough repairs so the old holes could no longer be used. 

• Assembly and Testing: After mounting the gear onto the shaft, we refitted the original stainless steel shim washers at both ends of the gear and applied high-viscosity grease for smooth operation. The gearbox was then reassembled and tested to confirm flawless functionality.

Results and Impact:

The project delivered exceptional results:

• Cost-Effective Solution: By replacing the damaged gear, we saved the client between $1,500–$2,500 compared to a complete awning replacement.

• Quick Turnaround: Our efficient process ensured minimal downtime for the client.

• Original Functionality: The restored gearbox operated as new, meeting the client’s needs without any compromises.

Beyond the immediate benefits, this project also avoided potential complications associated with replacing the entire awning, such as damaging bonding between brackets and body panels which in turn would create leaks and new problematic areas that would require extensive labor.

Do you have a challenging repair or custom part design in mind? Whether it’s reverse engineering or precision manufacturing, we’re here to help. Contact us today to explore how our advanced tools and expertise can save you time and money.

Frequently asked questions

Here are some common questions about these projects.

Can a 3D-printed gear be as strong as the original?

Yes, depending on the material used and the application. In this case, PETG provided a strong alternative suitable for the awning gearbox. For high-load applications, alternative materials like nylon or reinforced composites may be considered.

How long does it take to reverse-engineer and manufacture a replacement gear?

The turnaround time depends on the complexity of the part, but for this project, the process—including 3D scanning, CAD modeling, printing, and final assembly—was completed within a few days.

What are the benefits of 3D printing replacement parts over buying new ones?

3D printing allows for:

• Cost savings (avoiding expensive full replacements)

• Customization for perfect fitment

• Faster turnaround compared to ordering rare or discontinued parts

Will a 3D-printed part hold up under real-world use?

Yes, when designed and printed with the right materials. This gear was printed with 100% infill and bonded together with structural adhesive to ensure durability in its operating environment.

Can you create replacement parts for other camper components?

Yes, we can reverse-engineer and manufacture a wide range of custom parts for campers, vehicles, and machinery using 3D scanning, CAD, and advanced manufacturing techniques.

How can I get a custom part made for my own project?

If you need a custom part, simply reach out with photos and details. We can assess your needs and provide a tailored solution using 3D scanning, CAD modeling, and 3D printing.