Reverse Engineering & Re-Engineering of Kill Switch Hand Grip

The Challenge: To 3d scan and reverse engineer an organic shaped hand grip and re-engineer into a functioning 'kill switch' trigger grip. The grip chosen was an existing grip with known tried and tested grip ergonomics and feeling.

Actual grip to replicate

1. The grip was 3d scanned using white light scanner. Resultant point cloud geometry format stl mesh.

3d scan point cloud model

2. The stl point cloud scan was converted to usable CAD surfaces.

Re-engineered surface model from scan point cloud

3. The grip was re-engineered as a native CAD model. The design was further developed as two halves with integral 'kill switch' and trigger functionality.

CAD model of final grip design

4. Rendered images of the re-engineered grip were created for realistic visualisation for review and downstream marketing.

Rendered image showing final grip design.

5. A prototype of the grip was produced using our Markforged industrial 3d printer. Continuous carbon fibre layers were designed and embedded into the plastic matrix during printing to create a high strength functional working prototype.

Markforged 3d Print layer configuration, including continuous carbon fibre layers

Grip components on 3d print bed post printing

6. The prototype was mounted to the parent carbon composite assembly to undergo product testing.