The challenge
After upgrading our Genmitsu ProVerXL 4030 v2 to a larger four-foot by four-foot cutting area, we were left with a set of perfectly good lead screws and extrusions. Rather than let them sit idle, we wanted to reuse them to build a second machine. The problem was the brackets that tie all the aluminum extrusions together. Buying a whole new set would defeat the point of reusing parts we already had.
What we did
So instead of ordering replacements, we reverse-engineered them. We 3D scanned the original brackets to capture their exact geometry, then rebuilt each one in FreeCAD, keeping the fit identical to the factory parts with only minor refinements. The full set covers everything needed to assemble the frame: front brackets, rear brackets, X gantry brackets, and X gantry carrier brackets, two of each. The parts shown here are printed in PLA as working prototypes, with the finalized versions to be printed in PETG-CF for added strength.
3D scan
Capturing the exact geometry of the original bracket.
CAD model
The full set rebuilt in FreeCAD, ready to print or mill.
The result
The PLA prototypes fit the frame, but testing is still in progress. Load testing will follow before the design is finalized. The goal is a set of editable bracket designs that can be 3D printed or machined from aluminum.
Services used: 3D scanning, CAD design and reverse engineering, FDM 3D printing
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