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3D scanning, reverse engineering, and fabrication in 4130 Chromoly Steel
Reverse engineering project involving 3D scanning an original offroad vehicle control arm (four bar linkage) and redesigning it in 4130 Chromoly Steel for significantly improved durability. The original arm was scanned, measured, and used as a reference to build a new assembly from scratch in SolidWorks.
// Key Specifications
Original — 3D Scan
Redesigned — SolidWorks Assembly
Captured the existing suspension geometry to establish accurate mounting points, clearances, and baseline constraints for the new arm.
Reconstructed the OEM design intent, identifying key load paths and failure points to inform a stronger, more capable replacement.
Developed a fully parametric model, iterating on geometry to improve strength, clearance, and manufacturability.
Selected material based on strength-to-weight, weldability, and real-world abuse in off-road conditions.
Produced a detailed manufacturing package and coordinated with a fabricator to ensure the design intent was accurately realized.
Worked alongside the manufacturer during installation to verify fitment, alignment, and overall system performance.