At Black Widow Armoury, we also offer a professional reverse engineering and replacement part service for customers who have a damaged, broken, worn or discontinued component that is difficult — or sometimes impossible — to replace.

If you have a plastic or non-regulated part that has cracked, snapped, worn out or gone missing, you can send the original component to us. This could be a clip, cover, housing, insert, guide, spacer, mount, bracket, knob, protective cap, holder or many other types of small mechanical components.

Using high-precision 3D scanning technology, we can capture the shape and geometry of the original part and create an accurate digital 3D model. Our scanner uses blue laser technology, a method also widely used in industrial and manufacturing environments where highly precise dimensional measurement and quality control are required.

The scanner projects fine blue laser lines across the surface of the component while its optical sensors record the reflected light from multiple angles. This creates a dense three-dimensional representation of the object, allowing us to reproduce complex shapes, curves, openings, mounting points and other small details with a very high level of accuracy.

Where required, the scan is combined with additional physical measurements to help ensure the recreated model retains the correct dimensions, fit and geometry of the original component.

Why use reverse engineering?

Replacing an entire product because of one small broken component can be expensive and unnecessary. Our service may provide a practical alternative when:

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  the original spare part is no longer manufactured,
  

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  the manufacturer has discontinued the product,
  

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  the component is difficult to source,
  

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  replacement parts are unavailable in the UK,
  

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  an original component has become damaged or worn,
  

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  or purchasing an entirely new product simply because of one failed part does not make financial sense.
  

Our goal is to recreate the component as accurately as reasonably possible while preserving the dimensions and functional features required for the replacement to fit correctly.

More than just plastic parts

3D scanning is not limited to plastic components. In many cases, we can scan objects made from a wide variety of materials, including plastic, metal, rubber, composite materials, wood and other solid surfaces.

Depending on the surface finish, preparation may occasionally be required. Highly reflective, transparent or very dark surfaces can be more challenging for optical scanning, so specialist scanning preparation may be used where appropriate to achieve the best possible result.

This means that even if the original component is manufactured from a material that we do not intend to reproduce directly, it can often still be used as the physical reference for creating an accurate digital model.

From the original part to a new replacement

The process is straightforward:

1. Send us the original component

You contact us and provide details about the part and what has happened to it. If the project is suitable, the original or damaged component can be sent to us for assessment.

2. Precision 3D scanning and measurement

The component is scanned from multiple angles using high-resolution 3D scanning equipment. Where necessary, additional measurements are taken to verify critical dimensions.

3. Digital reconstruction

The scan data is processed into a detailed 3D model. Damaged areas can, where technically possible, be reconstructed based on the remaining geometry and available reference information.

4. Material selection

The most suitable printing material is selected depending on how the final component will be used.

5. Manufacturing and finishing

Once the model is ready, the replacement component can be produced using modern 3D printing technology and checked against the original geometry.

Different materials for different applications

Not every replacement component has the same requirements. Depending on the intended use, environment and mechanical demands, the finished product can be manufactured from different engineering and consumer-grade materials.

Options may include:

PLA / PLA 2.0+ – suitable for many general-purpose components where dimensional accuracy and a clean finish are important.

PETG – a strong and practical material offering good durability, impact resistance and improved temperature resistance compared with standard PLA.

Carbon-Fibre Reinforced Materials (CF) – available for applications where increased stiffness, strength and dimensional stability may be beneficial.

Other materials may also be available depending on the individual project and its requirements.

We assess each component individually and can recommend a material based on factors such as strength, flexibility, heat resistance, impact resistance, appearance and intended use.

One broken part does not always mean replacing everything

A small broken component can sometimes make an otherwise perfectly functional product unusable. Reverse engineering allows us to take an existing physical object and turn it into a reusable digital model, potentially allowing the replacement to be manufactured again in the future without needing to repeat the entire scanning process.

Whether you have an older discontinued product, a hard-to-find spare part, a damaged workshop component or a custom item that is no longer available, we may be able to help.

If you are unsure whether your part can be reproduced, get in touch with us. Send us photographs and a short description of the component, what it belongs to and which part is damaged, and we will assess whether the project is suitable for our reverse engineering service.

Have a broken or discontinued part? Contact Black Widow Armoury and let us see if we can bring it back to life.

Important Notice

Black Widow Armoury's reverse engineering service is provided for lawful, non-regulated components and accessories only.

We do not scan, reproduce or manufacture firearm components that are regulated, require a firearms licence, constitute a controlled component, or form an integral, pressure-bearing or safety-critical part of a firearm.

All projects are reviewed before being accepted.