Your Vision.
Our Engineering.
Reverse engineering, bespoke manufacture, and legacy system replacement for railway, mining, and marine equipment - from a single prototype to a production run, under full NDA protection.
Some engineering challenges do not fit a catalogue. When the part no longer exists, the standard product does not meet your specification, or the system needs engineering from the ground up, our Custom Projects team is where you start.
Identifying Your Custom
Engineering Requirements
Custom projects are not defined by size or budget. They are defined by the situation. If any of the three scenarios below describes your requirement, you are in the right place.
The Part You Need No Longer Exists
The original manufacturer has discontinued the component. No aftermarket equivalent is available. Drawings may or may not exist.
The equipment remains mechanically sound and operationally valuable, but cannot function due to a single missing component.
Reverse engineering and manufacturing the component to original specifications instead of replacing the entire asset.
The Standard Catalogue Does Not Meet Your Requirement
Available catalogue products do not meet required voltage, current, size, environmental, or signal specifications.
Adapting your system to fit a standard product introduces performance and reliability risks.
Custom-designed component engineered specifically for your application from the outset.
You Need Something Engineered from Scratch
A new product concept, system modification, prototype, or integrated solution not available in the market.
Off-the-shelf solutions cannot address the requirement.
End-to-end engineering support to convert your specification or idea into a fully developed and manufacturable product.
If none of these precisely describes your situation but the underlying problem feels familiar, contact us. We will listen and advise.
Contact Our TeamSix Types of Custom Project
We do not publish a project list because client confidentiality matters. What we can share is the type of challenges we are typically engaged to solve.
Reverse Engineering and Manufacture
Recreating components that no longer exist in the market, from sample or drawing.
We recreate components from samples, part numbers, or drawings, ensuring original fit, form, and function. Known failure modes are improved during redesign.
Manufactured component or assembly, CMM inspection report, material certificates, 2D drawings, and manufacturing package.
Bespoke Power Modules
Purpose-designed power conversion where catalogue products fall short.
Design and build rectifiers, inverters, and power modules tailored to exact voltage, current, size, and environmental requirements. Fully tested at rated conditions.
Custom power module, electrical test certificate, thermal validation data, and production documentation.
Custom Sensors and Instrumentation
Bespoke sensing solutions for non-standard and complex applications.
Design sensor assemblies for unique geometries, process conditions, and signal outputs. Validated for environment and measurement accuracy.
Custom sensor assembly, calibration certificate, installation drawing, and specification documentation.
Legacy Electronic System Replacement
Modern drop-in replacements for obsolete systems with no alternatives.
Engineer replacements matching original interfaces, including wiring adaptation and commissioning support.
Replacement system, wiring kit, installation documentation, commissioning record, and IRIS approval pathway support.
Rapid Prototype Development
Fast-track hardware development for validation and testing.
Parallel design, procurement, and build to accelerate prototype delivery. Includes iteration based on test feedback.
Working prototype, acceptance test report, and documented design iteration record.
Additional Capabilities
Specialist services beyond standard engineering categories.
Includes failure analysis, forensic investigation, DFM consultancy, test rig development, third-party design review, and localisation of technology.
Scope-dependent deliverables, always including a documented report or physical output as agreed.
From Sample to Production in Four Stages
Reverse engineering is not guesswork. It is a structured, documented process that produces a manufactured component with the same quality assurance as our standard catalogue.
Inputs
A sample component in any condition, a part number, an original drawing, or a verbal description. A physical sample is the most useful input but is not always available.
We assess the input against the target application and advise on the approach, timeline, and cost before any commitment is made. This initial assessment is obligation-free.
Advisory on feasibility and initial project estimate.
Measurement and Documentation
CMM measurement and 3D scanning. Material identification and functional characterisation covering electrical, mechanical, or sensing performance.
We produce a complete 2D drawing package and, where required, a 3D CAD model based on dimensional capture and material analysis.
Full 2D drawing package (PDF & native), CMM inspection report, and material analysis report.
Design and Validation
Manufacturing of a prototype or first article to the drawing package.
Validation against dimensional, functional, and environmental requirements. Design improvements are incorporated and validated at this stage.
First article component, acceptance test report, and design review record.
Production and Ongoing Supply
Full manufacturing release package including drawings, BOM, QC plan, and ATP.
Approved design released to production. We maintain the manufacturing documentation on file to support repeat orders at any future date.
Production components with full quality documentation and material certificates on every order.
Output files delivered in native CAD formats (SolidWorks, CATIA V5) and neutral formats (STEP, IGES). 2D drawings in PDF and DXF.
From Briefing to Delivery
Our project process is built for flexibility. We adapt our level of involvement to your needs, from a full turnkey engagement to technical support for your team.
Briefing
We listen to your challenge, understand your constraints, and define what success looks like in precise terms.
Written project definition covering requirements and feasibility.
Design
Engineers develop the solution with full transparency. reviews are milestone-gated. Nothing advances without approval.
Milestone-gated design review documentation at each stage.
Build
Prototypes and production units are built in our own facility using standard quality processes.
Prototype or production unit with build and quality records.
Test
Testing against agreed specifications covering functional, environmental, and lifetime performance.
Test report with pass/fail evidence, photographic and data records.
Deliver
Completed system delivery including documentation, training, and ongoing technical support.
Full documentation package and contact for ongoing support.
Custom Projects Across
Three Industries
Railway
Obsolete ALCO, EMD, and GE control electronics. Discontinued PCB assemblies for relay boards and control cards. Bespoke power conversion.
IRIS approval pathway (ISO/TS 22163), IS 8923 compliance, and EN 50155 environmental qualification.
Mining
ATEX-rated sensor assemblies for explosive zones. Custom enclosures for haul truck electrical systems in extreme dust and temperature.
ATEX Zone 0/1 design, IP67/68 rated enclosure design, and IEC 60068 environmental qualification.
Marine
Corrosion-resistant sensors for salt-air environments. Engine protection modules for unsupported legacy diesel platforms.
IEC 60945 awareness, Class society awareness (Lloyd's, BV, DNV), and conformal coating as standard.
Your Intellectual Property
Is Safe with Us
Custom projects frequently involve sensitive requirements. Confidentiality is not a courtesy; it is a legal commitment backed by our internal procedures.
Mutual NDA Available
We sign your NDA or provide our standard mutual NDA within 24 hours. No discussions begin without a signed agreement.
IP Belongs to You
All IP developed for your project belongs to you. We retain only generic engineering knowledge. No third-party disclosure.
Segregated Records
All documentation and communications are segregated and accessible only to assigned team members via access control.
Secure Data Handling
Files stored on encrypted servers with role-based access. Secure file transfer protocols used for all exchanges.
Start with a
Minimum Viable Enquiry
The belief that you need a fully formed specification to talk to us is a myth. You do not. Any of the following is sufficient to start a useful conversation.
What happens when you contact us?
We listen, ask clarifying questions, and tell you honestly if the project falls within our capabilities. The initial conversation is always obligation-free.
We will always tell you if your challenge is outside our capabilities, and try to point you in the right direction.
