Introduction
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.
Context
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.
Process
1. 3D Scanning: Using the Creaform HandyScan 700, we 3D-scanned the damaged gear. This ensured every detail was captured for the design phase.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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.
Call to Action:
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.
Summary
“See how we restored a camper awning gearbox by reverse-engineering an unusable gearbox component. Learn how advanced 3D scanning, CAD & Filament 3D Printing technologies provide cost-effective, reliable solutions for our clients.”
Restoring a Camper Awning Gearbox with Custom 3D-Printed Components