Functional Reconstruction of Oil Filter Cover

A replacement oil filter cover was needed for an older military vehicle where original parts were hard to source, CAD data did not exist, and low-volume production made traditional casting impractical.

• No existing CAD data
• Complex internal oil-flow geometry
• Hard-to-access regions between ribs and internal channels
• Low production volume making casting impractical

Available geometry was captured through 3D scanning, while inaccessible internal regions were reconstructed using manual measurement and functional redesign. Precision was applied selectively, focusing on mounting features and manufacturable performance.

1. 01

   Capture available external and internal geometry using structured-light scanning.

2. 02

   Identify areas where scan data was incomplete or unreliable.

3. 03

   Use manual measurement to recover critical dimensions for inaccessible features.

4. 04

   Rebuild the part in CAD using scan data as reference rather than final geometry.

5. 05

   Redesign internal oil channels based on functional flow requirements.

6. 06

   Produce a test print to validate fit and feasibility.

• Applied a hybrid scan-to-CAD workflow using both scan data and manual measurement.
• Reconstructed missing geometry through engineering judgment rather than exact scan replication.
• Focused precision on mounting holes while simplifying non-critical features.
• Adapted a cast component for additive manufacturing in low-volume production.
• Validated the result through test printing before production decision-making.

• Functional CAD reconstruction
• Manufacturable replacement-part concept
• Test-fit validation print

A functional CAD model was produced and validated through test printing, demonstrating a viable low-volume replacement strategy using additive manufacturing rather than cast reproduction.

• Scan data should be treated as reference, not ground truth.
• Engineering judgment is required to reconstruct missing geometry reliably.
• Not all part features require the same level of precision.
• Manufacturing method should influence reconstruction strategy from the start.