Broken, glued, and still had to be right — a fitting rescued from a bad scan
The part arrived damaged, with missing clips and visible glue repairs. The scan looked worse than the part. We rebuilt it inside a ±0.15 mm tolerance band — fully parametric, ready for production.
The problem
When a part shows up already broken and glued, every defect rides into the scan with it: non-manifold edges around the adhesive, deformed datums from warpage, and entire features missing on the broken side. There was no clean reference to copy from — the geometry had to be reconstructed from the surviving evidence and OEM context.
Our approach
- 1Health Wizard cleanup in Design X — non-manifold repair and targeted smoothing on adhesive blobs
- 2Three-point alignment to re-establish a reliable coordinate frame, ignoring regions warped beyond 0.1 mm RMS
- 3Mirrored intact section sketches to rebuild missing clips with OEM-spec fillets and draft
- 4Exact-surface fit on the deformed pocket, then knit back into the solid body with trim/extend
- 5LiveTransfer to SolidWorks so every feature stayed editable downstream
The result
Final accuracy stayed within ±0.15 mm and over 97 % of critical fitting points landed inside spec. The client received a clean parametric model where the original had only damaged plastic and brittle adhesive.
The deep-dive walkthrough of this case — the workflow, the screenshots, and the lessons we kept — lives on the blog.
Read on the blog
