Flashing Stator Parts: Root Cause Analysis and Permanent Resolution
Die Insert Reconstruction via 3D Laser Scanning and Reverse Engineering
When flashing reoccurs during production and reliable CAD documentation is unavailable, the solution is not a temporary ‘quick-fix’ repair.
The first step must be a geometric reconstruction — the foundation for a sound engineering decision.
client
Precision manufacturing company (Multinational background)
part
Overmolded stator with iron core
goal
Eliminating flashing, achieving production stability
technology
3D laser scanning and reverse engineering
The Challenge: Flashing Parts and Production Instability
Our partner contacted us regarding recurring flashing issues on an overmolded stator component. Following an audit of the production parameters, it became evident that the root cause was not a flaw in the process settings, but rather the result of a worn-out die insert.
- Quality issues and scrap
- Costly rework in mass production
- Risked delivery deadlines
Engineering Decision: Replacement vs. Repair
After a thorough assessment of the insert’s condition, two paths were available.
Our priority was to provide a long-term solution.
Welding and Remachining
- Time-consuming due to extensive surface wear
- Hard to execute on complex, intricate geometries
- Higher total cost with lower long-term reliability
RECOMMENDED SOLUTION
Full Replacement
- Stable geometry for flash-free sealing
- Precision through 3D laser scanning
- Permanent digital CAD model
- Fast ROI: Reduced scrap rates and zero manual deburring costs
3D Laser Scanning – Capturing the Physical Geometry
The worn insert was digitized using an industrial 3D laser scanner.
This step established the foundation for engineering reliability.
- High-Precision Data Capture
- Visual Identification of Worn Surfaces
- Reliable Digital Foundation for Manufacturing
Digital Reverse Engineering – Reconstructing Missing Geometry
Our engineers created reference geometry from the sections in good condition, then reconstructed the full model using symmetrical patterning.
The Result:
A manufacturable, flawless 3D model.
Wire EDM Correction – For a Perfect Fit
The new insert was manufactured based on the reconstructed model, but trial production revealed that the stator core fit required further fine-tuning.
- Modification of Critical Surfaces
- Applying Precise Offsets
- High-Precision Re-wire
Manufacturing Flexibility – Zero Downtime
The insert was removed only for the brief duration of the scanning process, ensuring the client’s production remained uninterrupted throughout the entire project.
Rapid Scanning
Seamless Series Production
Remanufacturing
Results
Whether it’s worn-out tool inserts, missing 3D documentation, or recurring quality issues
– our engineering team provides ready-to-implement solutions.
Don’t wait for scrap rates to rise—contact our experts for professional technological recovery!