Reverse engineering of obsolete spindles and motor spindles with no drawings available
When a spindle or motor spindle fails and neither the manufacturer nor any technical drawing still exists, Brochexpress reconstructs the part through reverse engineering: full measurement of the existing component, modelling, then manufacture of an identical or improved part.
The scenario of the untraceable component, with no original documentation
TLDR: An older machine, a manufacturer that has disappeared or been taken over several times, a drawing never supplied or long since lost: the failure of a spindle or motor spindle with no technical documentation available is a frequent situation in industry, particularly on machine fleets more than 15 to 20 years old.
Many machine tools remain in service long after their original manufacturer has disappeared, been bought by another group, or stopped producing the exact spindle or motor spindle reference installed. In these situations no technical drawing is available: neither from the machine builder (which may have disappeared or changed name several times), nor from the component supplier (often a subcontractor separate from the machine builder). The failed component is then the only remaining source of technical information — which makes reverse engineering the only viable route to a reliable replacement part.
How reverse engineering of a spindle or motor spindle works
TLDR: The process starts from the existing physical component, whether still working or definitively beyond use: full disassembly, precise dimensional survey of every part, identification of materials and heat treatments, then technical modelling allowing an identical part to be manufactured — or an improved one if the customer wishes.
Reverse engineering a spindle or motor spindle begins with completely dismantling the component, whether it is still in working order (which makes it easier to record operating clearances and tolerances) or definitively out of service (in which case the work relies on the remaining dimensions and metallurgical expertise on the existing parts). Every element — shaft, quill, rotor for a motor spindle, bearings, tool clamping system — is measured precisely, with identification of materials, heat treatments and original geometric tolerances. This survey phase results in a complete technical file (drawings, bill of materials, specifications) which then serves as the basis for manufacturing. Where the customer wishes, this stage is also an opportunity to incorporate technical improvements over the original design, without compromising compatibility with the existing machine.
What a reverse engineering project involves
- Analysis of the existing component, working or beyond use, as the sole technical reference
- Full dimensional survey of every part (shaft, bearings, clamping system, sealing)
- Identification of materials and treatments through metallurgical expertise where required
- Creation of a reference technical file, reusable for any future order
- Manufacture of an identical part, or one incorporating improvements agreed with the customer
When is reverse engineering the right solution?
Reverse engineering is particularly relevant when the machine builder has disappeared or been taken over several times without any transfer of technical documentation, when the original spindle or motor spindle supplier no longer exists or no longer produces that reference, or when the machine has been modified over time in ways that make the original drawings obsolete (assuming they still existed). It is less relevant if the original manufacturer or supplier can still supply a part or reliable technical documentation — in that case, ordering directly is generally quicker.
Frequently asked questions
Is reverse engineering possible if the spindle is definitively beyond use?
Yes, in most cases. The remaining dimensions, even on a damaged part, often allow the original dimensions to be reconstructed with the right expertise.
How long does a complete reverse engineering project take?
The lead time depends on the complexity of the spindle and the number of components to analyse. Contact us with the characteristics of your machine for an initial estimate.
Does the technical file produced by reverse engineering belong to me?
Ownership of the technical file is defined contractually on a case-by-case basis according to your project.
Can you improve the spindle compared with its original design during reverse engineering?
Yes, this is a frequently requested option: more speed, more power, or a different clamping system, while retaining compatibility with your existing machine.
Does reverse engineering also work for grinding or gear cutting spindles?
Yes, the method applies to any type of spindle or motor spindle, whatever the machining process (milling, turning, grinding, gear cutting).
Brochexpress, your solution when the original documentation no longer exists
Our design office and manufacturing workshop, based in Beaurepaire (France) and Lussery-Villars (Switzerland), reconstruct spindles and motor spindles of any brand and any generation from the existing component, even with no original documentation at all.
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